Recovery and re-use of waste energy in industrial facilities

ABSTRACT

Configurations and related processing schemes of specific direct or indirect inter-plants integration for energy consumption reduction synthesized for grassroots medium grade crude oil semi-conversion refineries to increase energy efficiency from specific portions of low grade waste heat sources are described. Configurations and related processing schemes of specific direct or indirect inter-plants integration for energy consumption reduction for integrated medium grade crude oil semi-conversion refineries and aromatics complex for increasing energy efficiency from specific portions of low grade waste sources are also described.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority under 35 U.S.C. §119 to U.S.Provisional Patent Application Ser. No. 62/209,217, filed on Aug. 24,2015; U.S. Provisional Patent Application Ser. No. 62/209,147, filed onAug. 24, 2015; U.S. Provisional Patent Application Ser. No. 62/209,188,filed on Aug. 24, 2015; and U.S. Provisional Patent Application Ser. No.62/209,223, filed on Aug. 24, 2015. The entire contents of each of thepreceding applications are incorporated herein by reference in theirrespective entireties.

TECHNICAL FIELD

This specification relates to operating industrial facilities, forexample, crude oil refining facilities or other industrial facilitiesthat include operating plants that generate heat.

BACKGROUND

Petroleum refining processes are chemical engineering processes andother facilities used in petroleum refineries to transform crude oilinto products, for example, liquefied petroleum gas (LPG), gasoline,kerosene, jet fuel, diesel oils, fuel oils, and other products.Petroleum refineries are large industrial complexes that involve manydifferent processing units and auxiliary facilities, for example,utility units, storage tanks, and other auxiliary facilities. Eachrefinery can have its own unique arrangement and combination of refiningprocesses determined, for example, by the refinery location, desiredproducts, economic considerations, or other factors. The petroleumrefining processes that are implemented to transform the crude oil intothe products such as those listed earlier can generate heat, which maynot be reused, and byproducts, for example, greenhouse gases (GHG),which may pollute the atmosphere. It is believed that the world'senvironment has been negatively affected by global warming caused, inpart, due to the release of GHG into the atmosphere.

SUMMARY

This specification describes technologies relating to specific direct orindirect inter-plants integration for energy consumption reduction fromwaste energy in industrial facilities.

The details of one or more implementations of the subject matterdescribed in this specification are set forth in the accompanyingdrawings and the description later. Other features, aspects, andadvantages of the subject matter will become apparent from thedescription, the drawings, and the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A-1N illustrate a first set of configurations and related schemedetails for thermally integrating different refining plants in the crudeoil refining facility.

FIGS. 1O-1AC illustrate a second set of configurations and relatedscheme details for thermally integrating different refining plants inthe crude oil refining facility.

FIGS. 1AD-1AK illustrate a third set configurations and related schemedetails for thermally integrating different refining plants in the crudeoil refining facility.

FIGS. 1AL-1AT illustrate a fourth set of configurations and relatedscheme details for thermally integrating different refining plants inthe crude oil refining facility.

FIGS. 1AU-1BB illustrate a fifth set of configurations and relatedscheme details for thermally integrating different refining plants inthe crude oil refining facility.

FIGS. 1BC-1BQ illustrate a sixth set of configurations and relatedscheme details for thermally integrating different refining plants inthe crude oil refining facility.

FIGS. 1BR-1BZ illustrate a seventh set of configurations and relatedscheme details for thermally integrating different refining plants inthe crude oil refining facility.

FIGS. 1CA-1CJ illustrate an eighth set of configurations and relatedscheme details for thermally integrating different refining plants inthe crude oil refining facility.

FIGS. 1CK-1CT illustrate a ninth set of configurations and relatedscheme details for thermally integrating different refining plants inthe crude oil refining facility.

FIGS. 1CU-1DF illustrate a tenth set of configurations and relatedscheme details for thermally integrating different refining plants inthe crude oil refining facility.

FIGS. 1DG-1DS illustrate an eleventh set of configurations and relatedscheme details for thermally integrating different refining plants inthe crude oil refining facility.

DETAILED DESCRIPTION

Industrial waste heat is a source for potential carbon-free powergeneration in many industrial facilities, for example, crude oilrefineries, petrochemical and chemical complexes, and other industrialfacilities. For example, a medium-size integrated crude oil refinerywith aromatics up to 4,000 MM British Thermal Units per hour (Btu/hr)can be wasted to a network of air coolers extended along the crude oiland aromatics site. Some of the wasted heat can be reused to heatstreams in refining sub-units of the crude oil refinery, therebydecreasing a quantity of heat that would otherwise need to be used toheat the streams. In this manner, a quantity of heat consumed by thecrude oil refinery can decrease. In addition, a quantity of greenhousegas (GHG) emission can also decrease. In some implementations, areduction of about 34% in heating utility consumption and a reduction ofabout 20% in cooling utility consumption can be achieved withoutaffecting an operational philosophy of the crude oil refinery.

The waste heat recovery and reuse techniques described here can beimplemented in medium grade crude oil refining semi-conversionfacilities and integrated medium grade crude oil refiningsemi-conversion oil refining and aromatics facilities. Theimplementations can result in energy efficient systems that can consumeabout 66% of the heating utility consumed by current state-of-the-artdesigns of existing and new crude oil refining facilities. Theimplementations can also result in decrease in pollution and in GHGemissions by about one-third relative to GHG emissions from currentstate-of-the-art designs of existing and new crude oil refiningfacilities.

In certain existing oil refining facilities, a stream in a plant (forexample, a naphtha hydro-treating plant, a sour water stripper plant, orother plant) is heated using heat energy generated in a steam reboiler.In some implementations of the subject matter described here, the streamin the plant can be heated using waste heat carried by another stream inanother plant (for example, a hydrocracking plant, a hydro-treatingplant, a hydrogen plant, or other plant). By doing so, the heat energygenerated in the steam reboiler can be decreased or eliminated. In otherwords, the steam reboiler need not be the only source of heat energy toheat the stream in the plant. The waste heat carried by the other streamin the other plant can either replace the heat energy generated in thesteam reboiler or supplement the heat energy thereby decreasing aquantity of heat energy needed from the steam reboiler.

The subject matter described here can be implemented at differentplants' specific operating modes and can be retrofitted without the needto change the network designs of existing heat exchanger designs incrude oil refineries. The minimum approach temperature used in the wasteheat recovery and reuse processes can be as low as 3° C. In someimplementations, higher minimum approach temperatures can be used in aninitial phase at the expense of less waste heat/energy recovery, whilerelatively better energy saving is realized in a subsequent phase uponusing the minimum approach temperature for the specific hot sourcesuses.

In sum, this disclosure describes several crude oil refinery-wideseparation/distillation networks, configurations, and processing schemesfor increasing energy efficiency of heating/cooling utilities. Theincrease in energy efficiency is realized by reusing all or part ofwaste heat, for example, low grade waste heat, carried by multiple,scattered low grade energy quality process streams.

Examples of Crude Oil Refinery Plants

1. Hydrogen Plant

Hydrogen is generally used in refineries for sulfur removal and qualityimprovement of hydrocarbon products. As sulfur restrictions on gasolineand diesel become stringent, the refining demand for hydrogen continuesto grow. Two process schemes are employed in on-purpose hydrogengeneration plants—conventional process and pressure swing adsorption(PSA) based process. Hydrogen production can includehydro-desulfurization, steam reforming, shift conversion andpurification. The conventional process produces a medium-purityhydrogen, whereas the PSA-based process recovers and purifies thehydrogen to high purities, for example, purities greater than 99.9%.

2. Aromatics Complex

A typical aromatics complex includes a combination of process units forthe production of basic petrochemical intermediates of benzene, tolueneand xylenes (BTX) using the catalytic reforming of naphtha usingcontinuous catalytic reformer (CCR) technology.

3. Gas Separation Plant

A gas separation plant includes a de-ethanizer and a de-propanizer,which are distillation columns used to isolate ethane and propane,respectively, in natural gas liquids (NGL) and light ends fractionationin gas plants and refineries. The de-ethanizer removes ethane from amixture of propane, butane and other heavier components. An output ofthe de-ethanizer is fed to a de-propanizer to separate propane from themixture.

4. Amine Regeneration Plant

Hydrogen sulfide and carbon dioxide are the most common contaminantspresent in natural gas and are present in relatively larger quantitiesthan other contaminants which can adversely impact the natural gasprocessing facility if not removed. Amine is used in an acid gasabsorber and regenerator to sweeten sour gases in a chemical process inwhich a weak base (for example, the amine) reacts with weak acids suchas hydrogen sulfide and carbon dioxide to form a weak salt.

5. Hydrocracking Plant

Hydrocracking is a two-stage process combining catalytic cracking andhydrogenation. In this process heavy feedstocks are cracked in thepresence of hydrogen to produce more desirable products. The processemploys high pressure, high temperature, a catalyst, and hydrogen.Hydrocracking is used for feedstocks that are difficult to process byeither catalytic cracking or reforming, since these feedstocks arecharacterized usually by high polycyclic aromatic content or highconcentrations of the two principal catalyst poisons, sulfur andnitrogen compounds (or combinations of them).

The hydrocracking process depends on the nature of the feedstock and therelative rates of the two competing reactions, hydrogenation andcracking. Heavy aromatic feedstock is converted into lighter productsunder a wide range of high pressures and high temperatures in thepresence of hydrogen and special catalysts. When the feedstock has ahigh paraffinic content, hydrogen prevents the formation of polycyclicaromatic compounds. Hydrogen also reduces tar formation and preventsbuildup of coke on the catalyst. Hydrogenation additionally convertssulfur and nitrogen compounds present in the feedstock to hydrogensulfide and ammonia. Hydrocracking produces iso-butane for alkylationfeedstock, and also performs isomerization for pour-point control andsmoke-point control, both of which are important in high-quality jetfuel.

6. Diesel Hydrotreating Plant

Hydrotreating is a refinery process for reducing sulfur, nitrogen andaromatics while enhancing cetane number, density and smoke point.Hydrotreating assists the refining industry's efforts to meet the globaltrend for stringent clean fuels specifications, the growing demand fortransportation fuels and the shift toward diesel. In this process, freshfeed is heated and mixed with hydrogen. Reactor effluent exchanges heatwith the combined feed and heats recycle gas and stripper charge.Sulphide (for example, ammonium bisulphide and hydrogen sulphide) isthen removed from the feed.

7. Sour Water Stripper Utility Plant (SWSUP)

The SWSUP receives sour water streams from acid gas removal, sulfurrecovery, and flare units, and the sour gas stripped and released fromthe soot water flash vessel. The SWSUP strips the sour components,primarily carbon dioxide (CO₂), hydrogen sulfide (H₂S) and ammonia(NH₃), from the sour water stream.

8. Sulfur Recovery Plant

Sulfur recovery facilities in refineries operate to regulate thedischarge of sulfur compounds to the atmosphere to meet environmentalregulations. In a sulfur recovery plant, combustion products thatinclude sulfur can be processed, for example, by heating, cooling withcondensers, using sulfur conversion catalyst, and by other processingtechniques. One technique is to use amines to extract the sulfur andother acid gas compounds.

9. Naphtha Hydrotreating Plant and Continuous Catalytic Reformer Plants

A Naphtha Hydrotreater (NHT) produces 101 Research Octane Number (RON)reformate, with a maximum 4.0 psi (pounds per square inch) Reid VaporPressure (RVP), as a blending stock in the gasoline pool. It usually hasthe flexibility to process blends of Naphtha from the Crude Unit, GasCondensate Splitter, Hydrocracker, Light Straight-Run Naphtha (LSRN) andVisbreaker Plants. The NHT processes naphtha to produce desulfurizedfeed for the CCR platformer and gasoline blending.

Heat Exchangers

In the configurations described in this disclosure, heat exchangers areused to transfer heat from one medium (for example, a stream flowingthrough a plant in a crude oil refining facility, a buffer fluid orother medium) to another medium (for example, a buffer fluid ordifferent stream flowing through a plant in the crude oil facility).Heat exchangers are devices which transfer (exchange) heat typicallyfrom a hotter fluid stream to a relatively less hotter fluid stream.Heat exchangers can be used in heating and cooling applications, forexample, in refrigerators, air conditions or other cooling applications.Heat exchangers can be distinguished from one another based on thedirection in which liquids flow. For example, heat exchangers can beparallel-flow, cross-flow or counter-current. In parallel-flow heatexchangers, both fluid involved move in the same direction, entering andexiting the heat exchanger side-by-side. In cross-flow heat exchangers,the fluid path runs perpendicular to one another. In counter-currentheat exchangers, the fluid paths flow in opposite directions, with onefluid exiting whether the other fluid enters. Counter-current heatexchangers are sometimes more effective than the other types of heatexchangers.

In addition to classifying heat exchangers based on fluid direction,heat exchangers can also be classified based on their construction. Someheat exchangers are constructed of multiple tubes. Some heat exchangersinclude plates with room for fluid to flow in between. Some heatexchangers enable heat exchange from liquid to liquid, while some heatexchangers enable heat exchange using other media.

Heat exchangers in crude oil refining and petrochemical facilities areoften shell and tube type heat exchangers which include multiple tubesthrough which liquid flows. The tubes are divided into two sets—thefirst set contains the liquid to be heated or cooled; the second setcontains the liquid responsible for triggering the heat exchange, thatis, the fluid that either removes heat from the first set of tubes byabsorbing and transmitting the heat away or warms the first set bytransmitting its own heat to the liquid inside. When designing this typeof exchanger, care must be taken in determining the correct tube wallthickness as well as tube diameter, to allow optimum heat exchange. Interms of flow, shell and tube heat exchangers can assume any of threeflow path patterns.

Heat exchangers in crude oil refining and petrochemical facilities canalso be plate and frame type heat exchangers. Plate heat exchangersinclude thin plates joined together with a small amount of space inbetween, often maintained by a rubber gasket. The surface area is large,and the corners of each rectangular plate feature an opening throughwhich fluid can flow between plates, extracting heat from the plates asit flows. The fluid channels themselves alternate hot and cold liquids,meaning that the heat exchangers can effectively cool as well as heatfluid. Because plate heat exchangers have large surface area, they cansometimes be more effective than shell and tube heat exchangers.

Other types of heat exchangers can include regenerative heat exchangersand adiabatic wheel heat exchangers. In a regenerative heat exchanger,the same fluid is passed along both sides of the exchanger, which can beeither a plate heat exchanger or a shell and tube heat exchanger.Because the fluid can get very hot, the exiting fluid is used to warmthe incoming fluid, maintaining a near constant temperature. Energy issaved in a regenerative heat exchanger because the process is cyclical,with almost all relative heat being transferred from the exiting fluidto the incoming fluid. To maintain a constant temperature, a smallquantity of extra energy is needed to raise and lower the overall fluidtemperature. In the adiabatic wheel heat exchanger, an intermediateliquid is used to store heat, which is then transferred to the oppositeside of the heat exchanger. An adiabatic wheel consists of a large wheelwith threats that rotate through the liquids—both hot and cold—toextract or transfer heat. The heat exchangers described in thisdisclosure can include any one of the heat exchangers described earlier,other heat exchangers, or combinations of them.

Each heat exchanger in each configuration can be associated with arespective thermal duty (or heat duty). The thermal duty of a heatexchanger can be defined as an amount of heat that can be transferred bythe heat exchanger from the hot stream to the cold stream. The amount ofheat can be calculated from the conditions and thermal properties ofboth the hot and cold streams. From the hot stream point of view, thethermal duty of the heat exchanger is the product of the hot stream flowrate, the hot stream specific heat, and a difference in temperaturebetween the hot stream inlet temperature to the heat exchanger and thehot stream outlet temperature from the heat exchanger. From the coldstream point of view, the thermal duty of the heat exchanger is theproduct of the cold stream flow rate, the cold stream specific heat anda difference in temperature between the cold stream outlet from the heatexchanger and the cold stream inlet temperature from the heat exchanger.In several applications, the two quantities can be considered equalassuming no heat loss to the environment for these units, particularly,where the units are well insulated. The thermal duty of a heat exchangercan be measured in watts (W), megawatts (MW), millions of BritishThermal Units per hour (Btu/hr), or millions of kilocalories per hour(Kcal/h). In the configurations described here, the thermal duties ofthe heat exchangers are provided as being “about X MW,” where “X”represents a numerical thermal duty value. The numerical thermal dutyvalue is not absolute. That is, the actual thermal duty of a heatexchanger can be approximately equal to X, greater than X or less thanX.

Configurations in which heat exchangers are described as being in seriescan have multiple implementations. In some implementations, the heatexchangers can be arranged in series in one order (for example, a firstheat exchanger, a second heat exchanger and a third heat exchanger inthat order) while in other implementations, the heat exchangers can bearranged in series in a different order (for example, a third heatexchanger, a first heat exchanger and a second heat exchanger in thatorder). In other words, a first heat exchanger described as being inseries with and downstream of a second heat exchanger in oneimplementation can be in series with and upstream of the second heatexchanger in a second, different implementation.

Flow Control System

In each of the configurations described later, process streams (alsocalled “streams”) are flowed within each plant in a crude oil refiningfacility and between plants in the crude oil refining facility. Theprocess streams can be flowed using one or more flow control systemsimplemented throughout the crude oil refining facility. A flow controlsystem can include one or more flow pumps to pump the process streams,one or more flow pipes through which the process streams are flowed andone or more valves to regulate the flow of streams through the pipes.

In some implementations, a flow control system can be operated manually.For example, an operator can set a flow rate for each pump and set valveopen or close positions to regulate the flow of the process streamsthrough the pipes in the flow control system. Once the operator has setthe flow rates and the valve open or close positions for all flowcontrol systems distributed across the crude oil refining facility, theflow control system can flow the streams within a plant or betweenplants under constant flow conditions, for example, constant volumetricrate or other flow conditions. To change the flow conditions, theoperator can manually operate the flow control system, for example, bychanging the pump flow rate or the valve open or close position.

In some implementations, a flow control system can be operatedautomatically. For example, the flow control system can be connected toa computer system to operate the flow control system. The computersystem can include a computer-readable medium storing instructions (suchas flow control instructions and other instructions) executable by oneor more processors to perform operations (such as flow controloperations). An operator can set the flow rates and the valve open orclose positions for all flow control systems distributed across thecrude oil refining facility using the computer system. In suchimplementations, the operator can manually change the flow conditions byproviding inputs through the computer system. Also, in suchimplementations, the computer system can automatically (that is, withoutmanual intervention) control one or more of the flow control systems,for example, using feedback systems implemented in one or more plantsand connected to the computer system. For example, a sensor (such as apressure sensor, temperature sensor or other sensor) can be connected toa pipe through which a process stream flows. The sensor can monitor andprovide a flow condition (such as a pressure, temperature, or other flowcondition) of the process stream to the computer system. In response tothe flow condition exceeding a threshold (such as a threshold pressurevalue, a threshold temperature value, or other threshold value), thecomputer system can automatically perform operations. For example, ifthe pressure or temperature in the pipe exceeds the threshold pressurevalue or the threshold temperature value, respectively, the computersystem can provide a signal to the pump to decrease a flow rate, asignal to open a valve to relieve the pressure, a signal to shut downprocess stream flow, or other signals.

This disclosure describes new energy efficient hydrocracking-basedconfigurations and related specific processing schemes for integratedmedium grade semi-conversion crude oil refining and aromatics complex.

In some implementations, a semi-conversion medium grade crude oilrefining facility includes an aromatics complex and a hydrocrackingplant. This disclosure describes a waste heat recovery and reuse networkfor such a refining facility. As described later, waste heat can berecovered from multiple plants in the crude oil refining facilityincluding a hydrocracking plant. Such a refinery typically consumesseveral hundred megawatts of energy in heating utilities. Implementingthe configurations described here can not only reduce energy consumptionbut also reduce energy-based greenhouse gas (GHG) emissions. Inparticular, this disclosure describes a method implemented in a crudeoil refining facility to heat multiple first streams in multiple firstplants of a crude oil refining facility using multiple second streams inmultiple second plants in the crude oil refining facility. Severalconfigurations of process schemes for doing so are described later withreference to the following figures.

Configuration 1

FIGS. 1A-1N illustrate configurations and related scheme details forthermally integrating different refining plants in the crude oilrefining facility. The thermal integration described in theseconfigurations and illustrated in FIGS. 1A-1N can reduce the crude oilrefining facility's energy consumption (for example, heating and coolingutilities). For example, a reduction in energy consumption by about 36MW, for example, 35.2 MW, can translate to at least about 6%, forexample, 5.4%, of the energy consumption in the crude oil refiningfacility. In certain schemes, a process stream (for example, a streamfrom one refining sub-unit of an aromatics plant or other processstreams) can be used to directly heat another process stream (forexample, a hydrocracking plant stream or other process stream). Incertain configurations, heat exchange between process streams can beimplemented using an intermediate buffer fluid, for example, water, oil,or other buffer fluid.

Configuration 1—Scheme A

In some implementations, multiple first streams in the multiple firstplants can be directly heated using multiple second streams in a secondplant. In some implementations, the multiple first plants can include asulfur recovery plant and an aromatics plant sub-unit including anaromatics complex benzene extraction unit. The second plant can includea hydrocracking plant.

FIGS. 1A-1D show a hydrocracking plant 712 in a crude oil refineryfacility. As shown in FIG. 1A, a second stage reaction section feed to asecond stage cold high pressure separator can directly heat a raffinatesplitter bottoms stream in a second heat exchanger with a thermal dutythat can range between about 5 MW and 15 MW (for example, 8.6 MW). Thetransfer of heat directly to another process streams captures heat thatwould have otherwise been discharged to the environment. The secondstage reaction section feed to a second stage cold high pressureseparator is returned to the hydrocracking plant 712 for furtherprocessing.

FIG. 1F shows an aromatics complex benzene extraction unit 718 in acrude oil refinery facility. The heated raffinate splitter bottomsstream can be flowed to the benzene extraction plant 718. The steam heatinput for the raffinate splitter can be 0 MW because the alternativeflow path disclosed in this configuration may satisfy the entire heatload for the operation of the column. In an alternative embodiment, thesteam heat input for the raffinate splitter can be reduced because thealternative flow path disclosed in this configuration may partiallysatisfy the heat load for the operation of the column.

As shown in FIG. 1B, a first stage reaction section feed to a firststage cold high pressure separator in the hydrocracking plant 712 candirectly heat an amine regenerator bottoms stream in a third heatexchanger with a thermal duty that can range between about 15 MW and 25MW (for example, 21 MW). The transfer of heat directly to anotherprocess streams captures heat that would have otherwise been dischargedto the environment. The first stage reaction section feed to a firststage cold high pressure separator is returned to the hydrocrackingplant 712 for further processing.

FIG. 1G shows a sulfur recovery plant 702 in a crude oil refineryfacility. The heated amine regenerator bottom stream can then be flowedto the sulfur recovery plant 702. The steam heat input for the amineregenerator can be 0 MW because the alternative flow path disclosed inthis configuration may satisfy the entire heat load for the operation ofthe column. In an alternative embodiment, the steam heat input for theamine regenerator can be reduced because the alternative flow pathdisclosed in this configuration may partially satisfy the heat load forthe operation of the column.

FIG. 1C (represented by FIGS. 1C-1 and 1C-2) show an operation schematicof the hydrocracking plant 712. As shown in FIG. 1D, a kerosene productstream in the hydrocracking plant 712 can directly heat a benzene columnbottoms stream in in a first heat exchanger with a thermal duty that canrange between about 1 MW and 10 MW (for example, 6 MW). The transfer ofheat directly to another process streams captures heat that would haveotherwise been discharged to the environment. The kerosene productstream is returned to the hydrocracking plant 712 for furtherprocessing.

FIG. 1E also shows an aromatics complex benzene extraction unit 718. Theheated benzene column bottoms stream can be flowed to the benzeneextraction plant 718 in the aromatics complex. The steam heat input forthe benzene column can be 0 MW because the alternative flow pathdisclosed in this configuration may satisfy the entire heat load for theoperation of the column. In an alternative embodiment, the steam heatinput for the benzene column can be reduced because the alternative flowpath disclosed in this configuration may partially satisfy the heat loadfor the operation of the column.

Such recovery and reuse of waste heat directly from the hydrocrackingplant can result in decreasing or eliminating the heat energy to heatthe sulfur recovery plant, the aromatics complex or a combinations ofthem such as by about 36 MW.

Configuration 1—Scheme B

In some implementations, the multiple first streams in the crude oilrefining facility such as those present in the multiple first plants,such as the aromatic complex sub-units such as the benzene extractionunit and the sulfur recovery plant, can be indirectly heated using themultiple second streams in a second plant, such as one or morehydrocracking plant, as heat energy sources.

Indirectly heating the streams can include heating the streams through abuffer fluid, for example, oil, water, or other buffer fluid. A bufferfluid (for example, high pressure water) from a buffer fluid tank (forexample, hot water tank) is flowed to the hydrocracking plant 712. Thebuffer fluid can be flowed into the plant as a single stream and splitinto multiple streams or it can be flowed into the plant as multiplestreams.

FIGS. 1H-1K shows a hydrocracking plant 712 in a crude oil refiningfacility. Specifically, FIG. 1H shows a first buffer fluid stream can beheated using a diesel product stream in a first heat exchanger with athermal duty that can range between about 5 MW and 15 MW (for example,9.4 MW). As shown in FIG. 1I, a second buffer fluid stream can be heatedusing a first stage reaction section feed to a first stage cold highpressure separator in a second heat exchanger with a thermal duty thatcan range between about 10 MW and 20 MW (for example, 15.6 MW). FIG. 1J(represented by FIGS. 1J-1 and 1J-2) show an operation schematic of thehydrocracking plant 712. As shown in 1K, a third buffer fluid stream canbe heated using a kerosene product stream in a third heat exchanger witha thermal duty that can range between about 5 MW and 15 MW (for example,9 MW). The diesel product stream, first stage reaction section feed to afirst stage cold high pressure separator and the kerosene product streamare each returned to the hydrocracking plant 712 for further processing.In all instances, the buffer fluid absorbs heat that would haveotherwise been discharged to the environment.

The first, second, and third heated buffer fluid streams are combinedinto a combined heated buffer fluid in a collection header. In thismanner, the first, second and third heat exchangers are parallel to oneanother relative to the flow of the buffer fluid.

The combined heated buffer fluid from the collection header (or in someembodiments, a heated or insulated buffer fluid tank or storage unitthat can hold heated collected buffer fluid for a period before use) canbe flowed to the sulfur recovery plant 702 or aromatics complex benzeneextraction unit 718 or combination thereof.

In an instance, the combined heated buffer fluid is flowed to thebenzene extraction unit 718. FIG. 1L shows an aromatics complex benzeneextraction unit 718 in a crude oil refining facility. The benzene columnbottoms stream is heated using the combined heated buffer fluid streamin a fourth heat exchanger with a thermal duty that can range betweenabout 1 MW and 10 MW (for example, 6 MW). The fourth heat exchanger iscoupled to, in series with and is downstream of the set of the first,second and third heat exchangers relative to the buffer fluid flow. Thesteam heat input for the benzene column can be 0 MW because thealternative flow path disclosed in this configuration may satisfy theentire heat load for the operation of the column. In an alternativeembodiment, the steam heat input for the benzene column can be reducedbecause the alternative flow path disclosed in this configuration maypartially satisfy the heat load for the operation of the column.

FIG. 1M also shows the aromatics complex benzene extraction unit 718. Araffinate splitter bottoms stream can be heated using the combinedheated buffer fluid branch in a fifth heat exchanger with a thermal dutythat can range between about 5 MW and 15 MW (for example, 8.6 MW). Thefifth heat exchanger is coupled to, in series with and is downstream ofthe set of the first, second and third heat exchangers relative to thebuffer fluid flow. The steam heat input for the raffinate splitter canbe 0 MW because the alternative flow path disclosed in thisconfiguration may satisfy the entire heat load for the operation of thecolumn. In an alternative embodiment, the steam heat input for theraffinate splitter can be reduced because the alternative flow pathdisclosed in this configuration may partially satisfy the heat load forthe operation of the column.

The combined heated buffer fluid is flowed to the sulfur recovery plant702. FIG. 1N shows the sulfur recovery plant 702 in a crude oil refiningfacility. An amine regenerator bottoms stream is heated using thecombined heated buffer fluid in a sixth heat exchanger with a thermalduty that can range between about 15 MW and 25 MW (for example, 21 MW).The sixth heat exchanger is coupled to, in series with and is downstreamof the set of the first, second and third heat exchangers relative tothe buffer fluid flow. The steam heat input for the amine regeneratorcan be 0 MW because the alternative flow path disclosed in thisconfiguration may satisfy the entire heat load for the operation of thecolumn. In an alternative embodiment, the steam heat input for the amineregenerator can be reduced because the alternative flow path disclosedin this configuration may partially satisfy the heat load for theoperation of the column.

The combined heated buffer fluid stream exiting the sixth heat exchangeris flowed to the collection header or the buffer fluid tank for reuse.In this manner, the fourth, fifth, and sixth heat exchangers are coupledto and are in series with each other relative to the flow of bufferfluid.

In some implementations, the heated buffer fluid can be flowed in seriesthrough the different plants. For example, the heated buffer fluid canbe flowed first to the sulfur recovery plant and then to the benzeneextraction unit. In another implementation, within the benzeneextraction unit the heated buffer fluid stream may flow through the heatexchangers in a different order as presented. The heated buffer fluidexiting the sixth heat exchanger can be flowed to a buffer fluid tank.The buffer fluid from the buffer fluid tank can then be flowed to thedifferent plants to restart the waste heat recovery and reuse cycle.

Such recovery and reuse of waste heat indirectly from the hydrocrackingplant can result in decreasing or eliminating the heat energy forheating the sulfur recovery plant, the aromatics complex or combinationsof them such as by about 36 MW.

Configuration 2

FIGS. 1O-1AC illustrate configurations and related scheme details forthermally integrating different refining plants in the crude oilrefining facility. The thermal integration described in theseconfigurations and illustrated in FIGS. 1O-1AC can reduce the crude oilrefining facility's energy consumption (for example, heating and coolingutilities). For example, a reduction in energy consumption by about 41MW, for example, 40.6 MW, can translate to at least about 7%, forexample, 7.2%, of the energy consumption in the crude oil refiningfacility. In certain schemes, a process stream (for example, a streamfrom one refining sub-unit of an aromatics plant or other processstreams) can be used to directly heat another process stream (forexample, a hydrocracking plant stream or other process stream). Incertain configurations, heat exchange between process streams can beimplemented using an intermediate buffer fluid, for example, water, oil,or other buffer fluid.

Configuration 2—Scheme A

In some implementations, multiple first streams in the multiple firstplants can be directly heated using multiple second streams in a secondplant. In some implementations, the multiple first plants can include asour water stripper plant and an aromatics plant sub-unit including anaromatic complex benzene extraction unit. The second plant can include ahydrocracking plant.

FIG. 1V shows a sour water stripper plant 710 in a crude oil refineryfacility. The sour water stripper bottoms stream can be flowed in theplant as a single stream and split into multiple streams or it can beflowed into the plant as multiple streams to facilitate heat recovery.

FIGS. 1O-1S show a hydrocracking plant 712 in a crude oil refineryfacility. As shown in FIG. 1O, a diesel product stream can directly heata first sour water stripper bottoms stream in a first heat exchangerwith a thermal duty that can range between about 5 MW and 15 MW (forexample, 10 MW). The transfer of heat directly to another processstreams captures heat that would have otherwise been discharged to theenvironment. The diesel product stream is returned to the hydrocrackingplant 712 for further processing.

As shown in FIG. 1P, a second stage reaction section feed to a secondstage cold high pressure separator can directly heat a raffinatesplitter bottom stream in a fifth heat exchanger with a thermal dutythat can range between about 5 MW and 15 MW (for example, 8.6 MW). Thetransfer of heat directly to another process streams captures heat thatwould have otherwise been discharged to the environment. The secondstage reaction section feed to the second stage cold high pressureseparator is returned to the hydrocracking plant 712 for furtherprocessing.

As shown in FIG. 1Q, a first stage reaction feed stream to first stagecold high pressure separator can directly heat a second sour waterstripper bottoms stream in a second heat exchanger with a thermal dutythat can range between about 15 MW and 25 MW (for example, 19.7 MW). Thetransfer of heat directly to another process streams captures heat thatwould have otherwise been discharged to the environment. The first stagereaction feed stream to the first stage cold high pressure separator isreturned to the hydrocracking plant 712 for further processing.

FIG. 1R (represented by FIGS. 1R-1 and 1R-2) show an operation schematicof the hydrocracking plant 712. As shown in FIG. 1S, a kerosene productstream can directly heat a third sour water stripper bottoms stream in athird heat exchanger having a thermal duty that can range between about1 MW and 10 MW (for example, 2.3 MW). The transfer of heat directly toanother process streams captures heat that would have otherwise beendischarged to the environment.

The kerosene product stream can also directly heat a benzene columnbottoms stream in a fourth heat exchanger having a thermal duty that canrange between about 1 MW and 10 MW (for example, 6 MW). The transfer ofheat directly to another process streams captures heat that would haveotherwise been discharged to the environment. The kerosene productstream is returned to the hydrocracking plant 712 for furtherprocessing.

As shown in FIG. 1S, the third heat exchanger is coupled to, in serieswith and is downstream of the fourth heat exchanger relative to the flowof kerosene product stream. In some implementations, the keroseneproduct stream can be flowed in series through the different plants. Forexample, the kerosene product stream is flowed first through the sourwater stripper heat exchanger and then through the aromatics complexheat exchanger. As shown in FIG. 1V, the three heated sour waterstripper bottoms streams are recombined and flowed to the sour waterstripper plant 710. In this manner, the first heat exchanger, the secondheat exchanger, and the third heat exchanger can be coupled to eachother in parallel relative to the flow of sour water stripper bottoms.The steam heat input for the sour water stripper can be 0 MW because thealternative flow path disclosed in this configuration may satisfy theentire heat load for the operation of the column. In an alternativeembodiment, the steam heat input for the sour water stripper can bereduced because the alternative flow path disclosed in thisconfiguration may partially satisfy the heat load for the operation ofthe column.

FIG. 1T shows an aromatics complex benzene extraction unit 718 in acrude oil refining facility. The heated benzene column bottoms streamcan be flowed to the benzene extraction plant 718. The steam heat inputfor the benzene column can be 0 MW because the alternative flow pathdisclosed in this configuration may satisfy the entire heat load for theoperation of the column. In an alternative embodiment, the steam heatinput for the benzene column can be reduced because the alternative flowpath disclosed in this configuration may partially satisfy the heat loadfor the operation of the column.

FIG. 1U also shows an aromatics complex benzene extraction unit 718. Theheated raffinate splitter column bottoms stream can be flowed to thebenzene extraction plant 718. The steam heat input for the raffinatesplitter can be 0 MW because the alternative flow path disclosed in thisconfiguration may satisfy the entire heat load for the operation of thecolumn. In an alternative embodiment, the steam heat input for theraffinate splitter can be reduced because the alternative flow pathdisclosed in this configuration may partially satisfy the heat load forthe operation of the column.

Such recovery and reuse of waste heat directly from the hydrocrackingplant can result in decreasing or eliminating the heat energy to heatthe aromatics complex, the sour water stripper plant or a combination ofthem such as by about 41 MW.

Configuration 2—Scheme B

In some implementations, the multiple first streams in the crude oilrefining facility such as those present in the multiple first plants,such as in the aromatic complex sub-units such as the benzene extractionunit and the sour water stripper plant, can be indirectly heated usingthe multiple second streams in a second plant, such as one or morehydrocracking plant, as heat energy sources.

Indirectly heating the streams can include heating the streams through abuffer fluid, for example, oil, water, or other buffer fluid. A bufferfluid (for example, high pressure water) from a buffer fluid tank (forexample, hot water tank) is flowed to the hydrocracking plant 712. Thebuffer fluid can be flowed into the plant as a single stream and splitinto multiple streams or it can be flowed into the plant as multiplestreams.

FIGS. 1W-1Z shows a hydrocracking plant 712 in a crude oil refiningfacility. Specifically, in FIG. 1W, a first buffer fluid stream can beheated using a diesel product stream in a first heat exchanger with athermal duty that can range between about 5 MW and 15 MW (for example,9.4 MW). As shown in FIG. 1X, a second buffer fluid stream can be heatedusing a first stage reaction section feed to a first stage cold highpressure separator in a second heat exchanger with a thermal duty thatcan range between about 10 MW and 20 MW (for example, 15.6 MW). As shownin FIG. 1Y (represented collectively by FIGS. 1Y-1 and 1Y-2)(specifically FIG. 1Y-1), a third buffer fluid stream can be heatedusing a product stripper overheads stream in a third heat exchanger witha thermal duty that can range between about 1 MW and 10 MW (for example,3.95 MW). As shown specifically in FIG. 1Y-2, a fourth buffer fluidbranch can be heated using a kerosene pumparound stream in a fourth heatexchanger with a thermal duty that can range between about 5 MW and 15MW (for example, 8.65 MW). As shown in FIG. 1Z, a fifth buffer fluidstream can be heated using a kerosene product stream in a fifth heatexchanger with a thermal duty that can range between about 5 MW and 15MW (for example, 9 MW). The diesel product stream, first stage reactionsection feed to a first stage cold high pressure separator, productstripper overheads stream, the kerosene pumparound stream and thekerosene product stream are each returned to the hydrocracking plant 712for further processing. In all instances, the buffer fluid absorbs heatthat would have otherwise been discharged to the environment.

The first, second, third, fourth and fifth heated buffer fluid streamsare combined into a combined heated buffer fluid in a collection header.In this manner, the first, second, third, fourth and fifth heatexchangers are parallel to one another relative to the flow of thebuffer fluid.

The combined heated buffer fluid from the collection header (or in someembodiments, a heated or insulated buffer fluid tank or storage unitthat can hold heated collected buffer fluid for a period before use) canbe flowed to the sour water stripper plant 710 or aromatics complexbenzene extraction unit 718 or combination thereof.

In an instance, the combined heated buffer fluid can be flowed to thebenzene extraction unit 718. FIG. 1AA shows an aromatics complex benzeneextraction unit 718 in a crude oil refining facility. The benzene columnbottoms stream can be heated using the combined heated buffer fluid in asixth heat exchanger with a thermal duty that can range between about 1MW and 10 MW (for example, 6 MW). The sixth heat exchanger is coupledto, in series with and is downstream of the set of first, second, third,fourth, and fifth heat exchanger relative to the flow of buffer fluid.The steam heat input for the benzene column can be 0 MW because thealternative flow path disclosed in this configuration may satisfy theentire heat load for the operation of the column. In an alternativeembodiment, the steam heat input for the benzene column can be reducedbecause the alternative flow path disclosed in this configuration maypartially satisfy the heat load for the operation of the column.

FIG. 1AB also shows the aromatics complex benzene extraction unit 718. Araffinate column bottoms stream can be heated using the combined heatedbuffer fluid in a seventh heat exchanger with a thermal duty that canrange between about 5 MW and 15 MW (for example, 8.6 MW). The seventhheat exchanger is coupled to, in series with and is downstream of theset of first, second, third, fourth, and fifth heat exchanger relativeto the flow of buffer fluid. The steam heat input for the raffinatecolumn can be 0 MW because the alternative flow path disclosed in thisconfiguration may satisfy the entire heat load for the operation of thecolumn. In an alternative embodiment, the steam heat input for theraffinate column can be reduced because the alternative flow pathdisclosed in this configuration may partially satisfy the heat load forthe operation of the column.

FIG. 1AC shows the sour water stripper plant 710 in a crude oil refiningfacility. The combined heated buffer fluid is flowed tot the sour waterstripper plant 710. A sour water stripper bottoms stream can be heatedusing the combined heated buffer fluid in an eighth heat exchanger witha thermal duty that can range between about 25 MW and 35 MW (forexample, 32 MW). The eighth heat exchanger is coupled to, in series withand is downstream of the set of first, second, third, fourth, and fifthheat exchanger relative to the flow of buffer fluid. The steam heatinput for the sour water stripper can be 0 MW because the alternativeflow path disclosed in this configuration may satisfy the entire heatload for the operation of the column. In an alternative embodiment, thesteam heat input for the sour water striper can be reduced because thealternative flow path disclosed in this configuration may partiallysatisfy the heat load for the operation of the column.

The combined heated buffer fluid after passing through the eighth heatexchanger is flowed back to the collection header or the buffer fluidtank for reuse. In this manner, the sixth, the seventh and the eighthheat exchanger are coupled to, in series with each other relative to theflow of buffer fluid.

In some implementations, the heated buffer fluid can be flowed in seriesthrough the different plants. For example, the heated buffer fluid canbe flowed first to the sour water stripper plant and then to the benzeneextraction unit. In another implementation, within the benzeneextraction unit the heated buffer fluid stream may flow through the heatexchangers in a different order as presented. The heated buffer fluidexiting the eighth heat exchanger can be flowed to a buffer fluid tank.The buffer fluid from the buffer fluid tank can then be flowed to thedifferent plants to restart the waste heat recovery and reuse cycle.

Such recovery and reuse of waste heat indirectly from the hydrocrackingplant can result in decreasing or eliminating the heat energy forheating the sour water stripper plant, the aromatics complex orcombinations of them such as by about 41 MW.

Configuration 3

FIGS. 1AD-1AK illustrate configurations and related scheme details forthermally integrating different refining plants in the crude oilrefining facility. The thermal integration described in theseconfigurations and illustrated in FIGS. 1AD-1AK can reduce the crude oilrefining facility's energy consumption (for example, heating and coolingutilities). For example, a reduction in energy consumption by about 50MW, for example, 49.8 MW, can translate to at least about 7%, forexample, 7.66%, of the energy consumption in the crude oil refiningfacility. In certain schemes, a process stream (for example, a streamfrom one refining sub-unit of an aromatics plant or other processstreams) can be used to directly heat another process stream (forexample, a hydrocracking plant stream or other process stream). Incertain configurations, heat exchange between process streams can beimplemented using an intermediate buffer fluid, for example, water, oil,or other buffer fluid.

Configuration 3—Scheme A

In some implementations, multiple first streams in the multiple firstplants can be directly heated using multiple second streams in a secondplant. In some implementations, the multiple first plants can include asulfur recovery plant, a gas separation plant and an aromatics plantsub-unit including an aromatics benzene extraction unit. The secondplant can include a hydrocracking plant.

FIGS. 1AD-1AG show a hydrocracking plant 712 in a crude oil refineryfacility. As shown in FIG. 1AD, a second stage reaction section feedstream to a second stage cold high pressure separator can directly heata C3/C4 splitter bottoms stream in a first heat exchanger with a thermalduty that can range between about 5 MW and 15 MW (for example, 9.9 MW).The transfer of heat directly to another process streams captures heatthat would have otherwise been discharged to the environment. The secondstage reaction section feed is returned to the hydrocracking plant 712for further processing.

As shown in FIG. 1AE, a first stage reaction feed stream to first stagecold high pressure separator can directly heat an amine regeneratorbottoms stream in a second heat exchanger with a thermal duty that canrange between about 15 MW and 25 MW (for example, 21 MW). The transferof heat directly to another process streams captures heat that wouldhave otherwise been discharged to the environment. The first stagereaction feed stream to first stage cold high pressure separator isreturned to the hydrocracking plant 712 for further processing.

As shown in FIG. 1AF (represented collectively by FIGS. 1AF-1 and 1AF-2)(specifically FIG. 1AF-2), a kerosene pumparound stream 712 can directlyheat a benzene column bottoms stream in a third heat exchanger with athermal duty that can range between about 1 MW and 10 MW (for example, 6MW). The transfer of heat directly to another process streams capturesheat that would have otherwise been discharged to the environment. Thekerosene pumparound stream is returned to the hydrocracking plant 712for further processing.

As shown in FIG. 1AG, the kerosene product stream can directly heat araffinate column bottoms stream in a fourth heat exchanger with thermalduty that can range between about 5 MW and 15 MW (for example, 8.6 MW.The transfer of heat directly to another process streams captures heatthat would have otherwise been discharged to the environment.

The kerosene product stream can also directly heat a de-ethanizer bottomstream in a fifth heat exchanger with a thermal duty that can rangebetween 1 MW and 10 MW (for example, 4.3 MW). The transfer of heatdirectly to another process streams captures heat that would haveotherwise been discharged to the environment. The kerosene productstream is returned to the hydrocracking plant 712 for furtherprocessing.

As shown in FIG. 1AG, the fifth heat exchanger is coupled to, in serieswith and is downstream of the fourth heat exchanger relative to the flowof kerosene product stream. In some implementations, the keroseneproduct stream can be flowed in series through the different plants. Forexample, the kerosene product stream is flowed first through thede-ethanizer heat exchanger and then through the aromatics complex heatexchanger.

FIG. 1AH shows a gas separation plant 704 in a crude oil refiningfacility. The heated C3/C4 splitter bottoms stream can be flowed to thegas separation plant 704. The steam heat input for the C3/C4 splittercan be 0 MW because the alternative flow path disclosed in thisconfiguration may satisfy the entire heat load for the operation of thecolumn. In an alternative embodiment, the steam heat input for the C3/C4splitter can be reduced because the alternative flow path disclosed inthis configuration may partially satisfy the heat load for the operationof the column.

Also in FIG. 1AH, the heated de-ethanizer bottoms stream can also beflowed to the gas separation plant 704. The steam heat input for thede-ethanizer column can be 0 MW because the alternative flow pathdisclosed in this configuration may satisfy the entire heat load for theoperation of the column. In an alternative embodiment, the steam heatinput for the de-ethanizer column can be reduced because the alternativeflow path disclosed in this configuration may partially satisfy the heatload for the operation of the column.

FIG. 1AI shows a sulfur recovery plant 702 in a crude oil refiningfacility. The heated amine regenerator bottoms stream can then be flowedto the sulfur recovery plant 702. The steam heat input for the amineregenerator can be 0 MW because the alternative flow path disclosed inthis configuration may satisfy the entire heat load for the operation ofthe column. In an alternative embodiment, the steam heat input for theamine regenerator can be reduced because the alternative flow pathdisclosed in this configuration may partially satisfy the heat load forthe operation of the column.

FIG. 1AJ shows an aromatics complex benzene extraction unit 718 in acrude oil refining facility. The heated benzene column bottoms streamcan be flowed to the benzene extraction plant 718. The steam heat inputfor the benzene column can be 0 MW because the alternative flow pathdisclosed in this configuration may satisfy the entire heat load for theoperation of the column. In an alternative embodiment, the steam heatinput for the benzene column can be reduced because the alternative flowpath disclosed in this configuration may partially satisfy the heat loadfor the operation of the column.

FIG. 1AK also shows an aromatics complex benzene extraction unit 718.The heated raffinate splitter bottoms stream can be flowed to thebenzene extraction plant 718. The steam heat input for the raffinatesplitter can be 0 MW because the alternative flow path disclosed in thisconfiguration may satisfy the entire heat load for the operation of thecolumn. In an alternative embodiment, the steam heat input for theraffinate splitter can be reduced because the alternative flow pathdisclosed in this configuration may partially satisfy the heat load forthe operation of the column.

Such recovery and reuse of waste heat directly from the hydrocrackingplant can result in decreasing or eliminating the heat energy to heatthe gas separation plant, an amine regeneration plant, a sulfur recoveryplant, the aromatics complex or a combinations of them such as by about50 MW.

Configuration 3—Scheme B

In some implementations, the multiple first streams in the crude oilrefining facility such as those present in the multiple first plants,such as in the sulfur recovery plant, a gas separation plant and anaromatics plant sub-unit including an aromatics benzene extraction unit,can be indirectly heated using the multiple second streams in a secondplant, such as one or more hydrocracking plant, as heat energy sources.

Indirectly heating the streams can include heating the streams through abuffer fluid, for example, oil, water, or other buffer fluid. A bufferfluid (for example, high pressure water) from a buffer fluid tank (forexample, hot water tank) is flowed to the hydrocracking plant 712. Thebuffer fluid can be flowed into the plant as a single stream and splitinto multiple streams or it can be flowed into the plant as multiplestreams.

To do so, one or more buffer fluid streams (for example, oil, water orother buffer fluid) can be heated using streams in the hydrocrackingplant using respective heat exchangers. The heated buffer fluids can becollected in a buffer fluid collection header. Streams in the gasseparation plant 704, the sulfur recovery plant 702 and the benzeneextraction unit 718 can be heated using branches of or the combinedheated buffer fluid in respective heat exchangers. The streams of or thecombined heated buffer fluid exiting the heat exchangers can be flowedto a buffer fluid tank. The buffer fluid from the buffer fluid tank canthen be flowed to the aromatics plant to restart the waste heat recoveryand reuse cycle.

Configuration 4

FIGS. 1AL-1AT illustrate configurations and related scheme details forthermally integrating different refining plants in the crude oilrefining facility. The thermal integration described in theseconfigurations and illustrated in FIGS. 1AL-1AT can reduce the crude oilrefining facility's energy consumption (for example, heating and coolingutilities). For example, a reduction in energy consumption by about 59MW, for example, 58.9 MW, can translate to at least about 9%, forexample, 9%, of the energy consumption in the crude oil refiningfacility. In certain schemes, a process stream (for example, a streamfrom one refining sub-unit of an aromatics plant or other processstreams) can be used to directly heat another process stream (forexample, a hydrocracking plant stream or other process stream). Incertain configurations, heat exchange between process streams can beimplemented using an intermediate buffer fluid, for example, water, oil,or other buffer fluid.

Configuration 4—Scheme A

In some implementations, multiple first streams in the multiple firstplants can be directly heated using multiple second streams in thesecond plant. In some implementations, the multiple first plants caninclude a sour water stripper plant, a naphtha hydrotreating plant andan aromatics complex sub-unit including an aromatic complex benzeneextraction plant. The multiple second plants can include a hydrocrackingplant

FIG. 1AQ shows a naphtha hydrotreating plant 714 in a crude oil refineryfacility. The naphtha splitter bottoms stream can be flowed in the plantas a single stream and split into multiple streams or it can be flowedinto the plant as multiple streams to facilitate heat recovery.

FIG. 1AR shows a sour water stripper plant 710 in a crude oil refineryfacility. The sour water stripper bottoms stream can be flowed in theplant as a single stream and split into multiple streams or it can beflowed into the plant as multiple streams to facilitate heat recovery.

FIGS. 1AL-1AP show a hydrocracking plant 712 in a crude oil refineryfacility. As shown in FIG. 1AL, a diesel product stream can directlyheat a first naphtha splitter bottom stream in a first heat exchangerwith a thermal duty that can range between about 1 MW and 10 MW (forexample, 6.6 MW). The transfer of heat directly to another processstreams captures heat that would have otherwise been discharged to theenvironment. The diesel product stream is returned to the hydrocrackingplant 712 for further processing.

As shown in FIG. 1AM, a second stage reaction feed stream to a secondstage cold high pressure separator can directly heat a raffinate columnbottoms stream in a second heat exchanger with a thermal duty that canrange between about 5 MW and 15 MW (for example, 8.6 MW). The transferof heat directly to another process streams captures heat that wouldhave otherwise been discharged to the environment. The second stagereaction feed is returned to the hydrocracking plant 712 for furtherprocessing.

As shown in FIG. 1AN, a first stage reaction feed stream to a firststage cold high pressure separator can directly heat a first sour waterstripper bottom stream in a third heat exchanger with a thermal dutythat can range between about 15 MW and 25 MW (for example, 20.5 MW). Thetransfer of heat directly to another process streams captures heat thatwould have otherwise been discharged to the environment. The first stagereaction feed to a first stage cold high pressure separator is returnedto the hydrocracking plant 712 for further processing.

As shown in FIG. 1AO (represented collectively by FIGS. 1AO-1 and 1AO-2)(specifically FIG. 1AO-1), a product stripper overheads stream candirectly heat a second sour water stripper bottoms stream in a fourthheat exchanger with a thermal duty that can range between about 5 MW and15 MW (for example, 11.5 MW). The transfer of heat directly to anotherprocess streams captures heat that would have otherwise been dischargedto the environment. The product stripper overheads stream is returned tothe hydrocracking plant 712 for further processing.

As shown in FIG. 1AO-2, a kerosene pumparound stream can directly heat asecond naphtha splitter bottoms stream in a fifth heat exchanger(thermal duty that can range between about 1 MW and 10 MW (for example,5.7 MW). The transfer of heat directly to another process streamscaptures heat that would have otherwise been discharged to theenvironment. The kerosene pumparound stream is returned to thehydrocracking plant 712 for further processing.

As shown in FIG. 1AP, the kerosene product stream can directly heat araffinate splitter bottom stream in a sixth heat exchanger with athermal duty that can range between about 1 MW and 10 MW (for example, 6MW). The transfer of heat directly to another process streams capturesheat that would have otherwise been discharged to the environment. Thekerosene product stream is returned to the hydrocracking plant 712 forfurther processing.

As shown in FIG. 1AQ, the two streams of the heated naphtha splitterbottoms streams are recombined and flowed to the naphtha hydrotreatingplant 714. In this manner, the first heat exchanger and the fifth heatexchanger can be coupled to each other in parallel relative to the flowof naphtha splitter bottoms. The steam heat input for the naphthasplitter can be 0 MW because the alternative flow path disclosed in thisconfiguration may satisfy the entire heat load for the operation of thecolumn. In an alternative embodiment, the steam heat input for henaphtha splitter can be reduced because the alternative flow pathdisclosed in this configuration may partially satisfy the heat load forthe operation of the column.

As shown in FIG. 1AQ, the two streams of the sour water stripper bottomsstreams are recombined and flowed to the sour water stripper plant 710.In this manner, the first heat exchanger and the second heat exchangercan be coupled to each other in parallel relative to the flow of sourwater stripper bottoms. The steam heat input for the sour water strippercan be 0 MW because the alternative flow path disclosed in thisconfiguration may satisfy the entire heat load for the operation of thecolumn. In an alternative embodiment, the steam heat input for the sourwater stripper can be reduced because the alternative flow pathdisclosed in this configuration may partially satisfy the heat load forthe operation of the column.

FIG. 1AT shows an aromatics complex benzene extraction unit 718 in acrude oil refining facility. The heated benzene column bottoms streamcan be flowed to the benzene extraction plant 718. The steam heat inputfor the benzene column can be 0 MW because the alternative flow pathdisclosed in this configuration may satisfy the entire heat load for theoperation of the column. In an alternative embodiment, the steam heatinput for the benzene column can be reduced because the alternative flowpath disclosed in this configuration may partially satisfy the heat loadfor the operation of the column.

FIG. 1AS also shows an aromatics complex benzene extraction unit 718.The heated raffinate splitter column bottom stream can be flowed to thebenzene extraction plant 718. The steam heat input for the raffinatesplitter can be 0 MW because the alternative flow path disclosed in thisconfiguration may satisfy the entire heat load for the operation of thecolumn. In an alternative embodiment, the steam heat input for theraffinate splitter can be reduced because the alternative flow pathdisclosed in this configuration may partially satisfy the heat load forthe operation of the column.

Such recovery and reuse of waste heat directly from the hydrocrackingplant can result in decreasing or eliminating the heat energy to heatthe aromatics complex, the sour water stripper plant, the naphthahydrotreating plant or a combination of them such as by about 59 MW.

Configuration 4—Scheme B

In some implementations, the multiple first streams in the crude oilrefining facility such as those present in the multiple first plants,such as in the naphtha hydrotreating plant, the sour water stripperplant, and an aromatics plant sub-unit including a benzene extractionunit, can be indirectly heated using the multiple second streams in asecond plant, such as one or more hydrocracking plant, as heat energysources.

Indirectly heating the streams can include heating the streams through abuffer fluid, for example, oil, water, or other buffer fluid. A bufferfluid (for example, high pressure water) from a buffer fluid tank (forexample, hot water tank) is flowed to the hydrocracking plant 712. Thebuffer fluid can be flowed into the plant as a single stream and splitinto multiple streams or it can be flowed into the plant as multiplestreams.

To do so, one or more buffer fluid streams (for example, oil, water orother buffer fluid) can be heated using streams in the hydrocrackingplant 712 using respective heat exchangers. The heated buffer fluids canbe collected in a buffer fluid collection header. Streams in the sourwater stripper plant 710, the naphtha hydrotreating plant 714 and thearomatic complex benzene extraction plant 718 can be heated using theheated buffer fluid in respective heat exchangers. The heated bufferfluid exiting the heat exchangers can be flowed to a buffer fluid tank.The buffer fluid from the buffer fluid tank can then be flowed to thearomatics plant to restart the waste heat recovery and reuse cycle.

Configuration 5

FIGS. 1AU-1BB illustrate configurations and related scheme details forthermally integrating different refining plants in the crude oilrefining facility. The thermal integration described in theseconfigurations and illustrated in FIGS. 1AU-1BB can reduce the crude oilrefining facility's energy consumption (for example, heating and coolingutilities). For example, a reduction in energy consumption by about 61MW, which translates to at least about 9% of the energy consumption inthe crude oil refining facility. In certain schemes, a process stream(for example, a stream from one refining sub-unit of an aromatics plantor other process streams) can be used to directly heat another processstream (for example, a hydrocracking plant stream or other processstream). In certain configurations, heat exchange between processstreams can be implemented using an intermediate buffer fluid, forexample, water, oil, or other buffer fluid.

Configuration 5—Scheme A

In some implementations, multiple first streams in the multiple firstplants can be directly heated using multiple second streams in thesecond plant. In some implementations, the multiple first plants caninclude a sour water stripper plant, a gas separation plant and anaromatics complex sub-unit including an aromatic complex benzeneextraction unit. The second plant can include a hydrocracking plant.

FIG. 1AY shows a sour water stripper plant 710 in a crude oil refineryfacility. The sour water stripper bottoms stream can be flowed in theplant as a single stream and split into multiple streams or it can beflowed into the plant as multiple streams to facilitate heat recovery.

FIGS. 1AU-1AX show a hydrocracking plant 712 in a crude oil refineryfacility. As shown in FIG. 1AU, a second stage reaction feed stream to asecond stage cold high pressure separator can directly heat a C3/C4splitter bottoms stream in a third heat exchanger with a thermal dutythat can range between about 5 MW and 15 MW (for example, 9.9 MW). Thetransfer of heat directly to another process streams captures heat thatwould have otherwise been discharged to the environment. The secondstage reaction feed to a second stage cold high pressure separator isreturned to the hydrocracking plant 712 for further processing.

As shown in FIG. 1AV, a first stage reaction feed stream to a firststage cold high pressure separator can directly heat a first sour waterstripper bottom stream in a second heat exchanger with a thermal dutythat can range between about 15 MW and 25 MW (for example, 20.5 MW). Thetransfer of heat directly to another process streams captures heat thatwould have otherwise been discharged to the environment. The first stagereaction feed stream to a first stage cold high pressure separator isreturned to the hydrocracking plant 712 for further processing.

As shown in FIG. 1AW (represented collectively by FIGS. 1AW-1 and 1AW-2)(specifically FIG. 1AW-1), a product stripper overheads stream candirectly heat a second sour water stripper bottoms stream in a firstheat exchanger with a thermal duty that can range between about 5 MW and15 MW (for example, 11.5 MW). The transfer of heat directly to anotherprocess streams captures heat that would have otherwise been dischargedto the environment. The product stripper overheads stream is returned tothe hydrocracking plant 712 for further processing.

As shown specifically in FIG. 1AW-2, a kerosene pumparound stream canheat a benzene column bottoms stream in a sixth heat exchanger with athermal duty that can range between about 1 MW and 10 MW (for example, 6MW). The transfer of heat directly to another process streams capturesheat that would have otherwise been discharged to the environment. Thekerosene pumparound stream is returned to the hydrocracking plant 712for further processing.

As shown in FIG. 1AX, the kerosene product stream can heat a raffinatesplitter bottom in a fourth heat exchanger that has a thermal duty thatcan range between about 5 MW and 15 MW (for example, 8.6 MW). Thekerosene product stream can also heat a de-ethanizer column bottomstream in a fifth heat exchanger having a thermal duty that can rangebetween about 1 MW and 10 MW (for example, 4.3 MW). The transfer of heatdirectly to another process streams captures heat that would haveotherwise been discharged to the environment. The kerosene productstream is returned to the hydrocracking plant 712 for furtherprocessing.

As shown in FIG. 1AX, the fifth heat exchanger is coupled to, in serieswith and is downstream of the fourth heat exchanger relative to the flowof kerosene product stream. In some implementations, the keroseneproduct stream can be flowed in series through the different plants. Forexample, the kerosene product stream is flowed first through thede-ethanizer heat exchanger and then through the aromatics complex heatexchanger.

FIG. 1BB shows an aromatics complex benzene extraction unit 718 in acrude oil refining facility. The heated benzene column bottoms streamcan be flowed to the benzene extraction unit 718. The steam heat inputfor the benzene column can be 0 MW because the alternative flow pathdisclosed in this configuration may satisfy the entire heat load for theoperation of the column. In an alternative embodiment, the steam heatinput for the benzene column can be reduced because the alternative flowpath disclosed in this configuration may partially satisfy the heat loadfor the operation of the column.

FIG. 1AZ also shows an aromatics complex benzene extraction unit 718.The heated raffinate splitter column bottom stream can be flowed to thebenzene extraction unit 718. The steam heat input for the raffinatesplitter can be 0 MW because the alternative flow path disclosed in thisconfiguration may satisfy the entire heat load for the operation of thecolumn. In an alternative embodiment, the steam heat input for theraffinate splitter can be reduced because the alternative flow pathdisclosed in this configuration may partially satisfy the heat load forthe operation of the column.

FIG. 1BA shows a gas separation plant 704 in a crude oil refiningfacility. The heated C3/C4 splitter bottoms stream can be flowed to thegas separation plant 704. The steam heat input for the C3/C4 splittercan be 0 MW because the alternative flow path disclosed in thisconfiguration may satisfy the entire heat load for the operation of thecolumn. In an alternative embodiment, the steam heat input for the C3/C4splitter can be reduced because the alternative flow path disclosed inthis configuration may partially satisfy the heat load for the operationof the column.

Also shown in FIG. 1BA, the heated de-ethanizer bottoms stream can alsobe flowed to the gas separation plant 604. The steam heat input for thede-ethanizer column can be 0 MW because the alternative flow pathdisclosed in this configuration may satisfy the entire heat load for theoperation of the column. In an alternative embodiment, the steam heatinput for the de-ethanizer column can be reduced because the alternativeflow path disclosed in this configuration may partially satisfy the heatload for the operation of the column.

As shown in FIG. 1AQ, the two sour water stripper bottoms streams arerecombined and can be flowed to the sour water stripper plant 710. Inthis manner, the first heat exchanger and the second heat exchanger canbe coupled to each other in parallel relative to the flow of sour waterstripper bottoms. The steam heat input for the sour water stripper canbe 0 MW because the alternative flow path disclosed in thisconfiguration may satisfy the entire heat load for the operation of thecolumn. In an alternative embodiment, the steam heat input for the sourwater stripper can be reduced because the alternative flow pathdisclosed in this configuration may partially satisfy the heat load forthe operation of the column.

Such recovery and reuse of waste heat directly from the hydrocrackingplant can result in decreasing or eliminating the heat energy to heatthe aromatics complex, the sour water stripper plant, the gas separationplant or a combination of them such as by about 61 MW.

Configuration 5—Scheme B

In some implementations, the multiple streams in the crude oil refiningfacility such as those present in the multiple first plants, such as insour water stripper plant, the gas separation plant and the an aromaticscomplex sub-unit including an aromatic complex benzene extraction unitcan be indirectly heated using the multiple second streams in a secondplant, such as one or more hydrocracking plant, as heat energy sources.

Indirectly heating the streams can include heating the streams through abuffer fluid, for example, oil, water, or other buffer fluid. A bufferfluid (for example, high pressure water) from a buffer fluid tank (forexample, hot water tank) is flowed to the hydrocracking plant 712. Thebuffer fluid can be flowed into the plant as a single stream and splitinto multiple streams or it can be flowed into the plant as multiplestreams.

To do so, one or more buffer fluid streams (for example, oil, water orother buffer fluid) can be heated using streams in the hydrocrackingplant 712 using respective heat exchangers. The heated buffer fluids canbe collected in a buffer fluid collection header. Streams in the sourwater stripper plant 710, the gas separation plant 704 and the benzeneextraction plant 718 can be heated using the heated buffer fluid streamsin respective heat exchangers. The heated buffer fluid exiting the heatexchangers can be flowed to a buffer fluid tank. The buffer fluid fromthe buffer fluid tank can then be flowed to the aromatics plant torestart the waste heat recovery and reuse cycle.

Configuration 6

FIGS. 1BC-1BQ illustrate configurations and related scheme details forthermally integrating different refining plants in the crude oilrefining facility. The thermal integration described in theseconfigurations and illustrated in FIGS. 1BC-1BQ can reduce the crude oilrefining facility's energy consumption (for example, heating and coolingutilities). For example, a reduction in energy consumption by about 62MW, for example, 62.4 MW, can translate to at least about 9%, forexample, 9.6%, of the energy consumption in the crude oil refiningfacility. In certain schemes, a process stream (for example, a streamfrom one refining sub-unit of an aromatics plant or other processstreams) can be used to directly heat another process stream (forexample, a hydrocracking plant stream or other process stream). Incertain configurations, heat exchange between process streams can beimplemented using an intermediate buffer fluid, for example, water, oil,or other buffer fluid.

Configuration 6—Scheme A

In some implementations, multiple first streams in the multiple firstplants can be directly heated using multiple second streams in thesecond plant. In some implementations, the multiple first plants caninclude an amine regeneration plant and an aromatics plant sub-unitincluding an aromatic complex benzene extraction unit. The second plantcan include a hydrocracking plant.

FIG. 1BI shows an amine regeneration plant 706 in a crude oil refineryfacility. The acid gas regenerator bottoms stream can be flowed in theplant as a single stream and split into multiple streams or it can beflowed into the plant as multiple streams to facilitate heat recovery.

FIGS. 1BC-1BF show a hydrocracking plant 712 in a crude oil refineryfacility. As shown in FIG. 1BC, a second stage reaction feed stream to asecond stage cold high pressure separator can directly heat a raffinatesplitter bottoms stream in a first heat exchanger with a thermal dutythat can range between about 5 MW and 15 MW (for example, 8.6 MW). Thetransfer of heat directly to another process streams captures heat thatwould have otherwise been discharged to the environment. The secondstage reaction feed stream to a second stage cold high pressureseparator is returned to the hydrocracking plant 712 for furtherprocessing.

As shown in FIG. 1BD, a first stage reaction feed stream to a firststage cold high pressure separator can directly heat a first acid gasregenerator bottom streams in a second heat exchanger with a thermalduty that can range between about 25 MW and 35 MW (for example, 27.8MW). The transfer of heat directly to another process streams capturesheat that would have otherwise been discharged to the environment. Thefirst stage reaction feed stream to a first stage cold high pressureseparator is returned to the hydrocracking plant 712 for furtherprocessing.

As shown in FIG. 1BE (represented collectively by FIGS. 1BE-1 and 1BE-2)(specifically FIG. 1BE-1), a product stripper overheads stream candirectly heat a second acid gas regenerator bottoms stream in a thirdheat exchanger with a thermal duty that can range between about 10 MWand 20 MW (for example, 14.8 MW). The transfer of heat directly toanother process streams captures heat that would have otherwise beendischarged to the environment. The product stripper overheads stream isreturned to the hydrocracking plant 712 for further processing.

As shown in FIG. 1BF, a kerosene product stream can directly heat athird acid gas regenerator bottoms stream in a fourth heat exchanger(thermal duty that can range between about 1 MW and 10 MW (for example,5.2 MW)). The transfer of heat directly to another process streamscaptures heat that would have otherwise been discharged to theenvironment.

The kerosene product stream can also directly heat a benzene columnbottoms stream in a fifth heat exchanger with a thermal duty that canrange between about 1 MW and 10 MW (for example, 6 MW). The transfer ofheat directly to another process streams captures heat that would haveotherwise been discharged to the environment. The kerosene productstream is returned to the hydrocracking plant 712 for furtherprocessing.

As shown in FIG. 1BF, the fourth heat exchanger is coupled to, in serieswith and is downstream of the fifth heat exchanger relative to the flowof kerosene product stream. In some implementations, the keroseneproduct stream can be flowed in series through the different plants. Forexample, the kerosene product stream is flowed first through the acidgas regenerator heat exchanger and then through the aromatics complexheat exchanger.

FIG. 1BG shows an aromatics complex benzene extraction unit 718 in acrude oil refining facility. The heated benzene column bottom stream canbe flowed to the benzene extraction plant 718. The steam heat input forthe benzene column can be 0 MW because the alternative flow pathdisclosed in this configuration may satisfy the entire heat load for theoperation of the column. In an alternative embodiment, the steam heatinput for the benzene column can be reduced because the alternative flowpath disclosed in this configuration may partially satisfy the heat loadfor the operation of the column.

FIG. 1BH also shows an aromatics complex benzene extraction unit 718.The heated raffinate splitter column bottom stream can be flowed to thebenzene extraction plant 718. The steam heat input for the raffinatesplitter can be 0 MW because the alternative flow path disclosed in thisconfiguration may satisfy the entire heat load for the operation of thecolumn. In an alternative embodiment, the steam heat input for theraffinate splitter can be reduced because the alternative flow pathdisclosed in this configuration may partially satisfy the heat load forthe operation of the column.

As shown in FIG. 1BI, the three streams of the heated acid gasregenerator bottoms are recombined and flowed to the amine regenerationplant 706. In this manner, the first heat exchanger, the second heatexchanger, and the third heat exchanger can be coupled to each other inparallel relative to the flow of acid gas regenerator bottoms. The steamheat input for the acid gas regenerator can be 0 MW because thealternative flow path disclosed in this configuration may satisfy theentire heat load for the operation of the column. In an alternativeembodiment, the steam heat input for the acid gas regenerator can bereduced because the alternative flow path disclosed in thisconfiguration may partially satisfy the heat load for the operation ofthe column.

Such recovery and reuse of waste heat directly from the hydrocrackingplant can result in decreasing or eliminating the heat energy to heatthe aromatics complex, an amine regeneration plant, or a combination ofthem, such as by about 62 MW.

Configuration 6—Scheme B

In some implementations, the multiple first streams in the crude oilrefining facility such as those present in the multiple first plants,such as in the aromatic complex sub-units such as the benzene extractionunit and the amine regeneration plant, can be indirectly heated usingthe multiple second streams in a second plant, such as one or morehydrocracking plant, as heat energy sources

Indirectly heating the streams can include heating the streams through abuffer fluid, for example, oil, water, or other buffer fluid. A bufferfluid (for example, high pressure water) from a buffer fluid tank (forexample, hot water tank) is flowed to the hydrocracking plant 712. Thebuffer fluid can be flowed into the plant as a single stream and splitinto multiple streams or it can be flowed into the plant as multiplestreams.

FIGS. 1BJ-1BN shows a hydrocracking plant 712 in a crude oil refiningfacility. Specifically, in FIG. 1BJ, a first buffer fluid stream can beheated using a diesel product stream in a first heat exchanger with athermal duty that can range between about 5 MW and 15 MW (for example,10.87 MW). In an alternative embodiment, the cooling requirement of thediesel product stream can be 0 MW because the alternative flow pathdisclosed in this configuration may satisfy the entire coolingrequirement for the diesel product stream. As shown in FIG. 1BK, asecond buffer fluid stream can be heated using a second reaction stagefeed stream to a second stage cold high pressure separator in a secondheat exchanger with a thermal duty that can range between about 5 MW and15 MW (for example, 7.3 MW). As shown in FIG. 1BL, a third buffer fluidstream can be heated using a first reaction section feed stream to afirst stage cold high pressure separator stream in a third heatexchanger with a thermal duty that can range between about 20 MW and 30MW (for example, 23.8 MW). As shown in FIG. 1BM (representedcollectively by FIGS. 1BM-1 and 1BM-2) (specifically FIG. 1BM-2), afourth buffer fluid stream can be heated using a kerosene pumparoundstream in a fourth heat exchanger with a thermal duty that can rangebetween about 5 MW and 15 MW (for example, 10.2 MW). In an embodiment,the cooling requirement of the kerosene pumparound stream can be 0 MWbecause the alternative flow path disclosed in this configuration maysatisfy the entire cooling requirement for the kerosene pumparoundstream for the operation of the fractionator column. As shown in FIG.1BN, a fifth buffer fluid stream can be heated using a kerosene productstream in a fifth heat exchanger with a thermal duty that can rangebetween about 5 MW and 15 MW (for example, 11 MW) (FIG. 1BN). The dieselproduct stream, second reaction stage feed stream to a second stage coldhigh pressure separator, first stage reaction section feed to a firststage cold high pressure separator, the kerosene pumparound stream andthe kerosene product stream are each returned to the hydrocracking plant712 for further processing. In all instances, the buffer fluid absorbsheat that would have otherwise been discharged to the environment.

The first, second, third, fourth and fifth heated buffer fluid streamsare combined into a combined heated buffer fluid in a collection header.In this manner, the first, second, third, fourth and fifth heatexchangers are parallel to one another relative to the flow of thebuffer fluid.

The combined heated buffer fluid from the collection header (or in someembodiments, a heated or insulated buffer fluid tank or storage unitthat can hold heated collected buffer fluid for a period before use) canbe flowed to the amine regeneration plant 706 or aromatics complexbenzene extraction unit 718 or combination thereof

In an instance, the combined heated buffer fluid can be flowed to thebenzene extraction unit 718. FIG. 1BO shows an aromatics complex benzeneextraction unit 718 in a crude oil refining facility. The benzene columnbottoms stream can be heated using the combined heated buffer fluid in asixth heat exchanger with a thermal duty that can range between about 1MW and 10 MW (for example, 6 MW). The sixth heat exchanger is coupledto, in series with and is downstream of the set of first, second, third,fourth, and fifth heat exchangers relative to the flow of buffer fluid.The steam heat input for the benzene column can be 0 MW because thealternative flow path disclosed in this configuration may satisfy theentire heat load for the operation of the column. In an alternativeembodiment, the steam heat input for the benzene column can be reducedbecause the alternative flow path disclosed in this configuration maypartially satisfy the heat load for the operation of the column.

FIG. 1BP also shows the aromatics complex benzene extraction unit 718. Araffinate column bottoms stream can be heated using the combined heatedbuffer fluid in a seventh heat exchanger with a thermal duty that canrange between about 5 MW and 15 MW (for example, 8.6 MW). The seventhheat exchanger is coupled to, in series with and is downstream of theset of first, second, third, fourth, and fifth heat exchanger relativeto the flow of buffer fluid. The steam heat input for the raffinatecolumn can be 0 MW because the alternative flow path disclosed in thisconfiguration may satisfy the entire heat load for the operation of thecolumn. In an alternative embodiment, the steam heat input for theraffinate column can be reduced because the alternative flow pathdisclosed in this configuration may partially satisfy the heat load forthe operation of the column.

FIG. 1BQ shows the amine regeneration plant 706 in a crude oil refiningfacility. The combined heated buffer fluid is flowed tot the amineregeneration plant 706. As shown in FIG. 1BQ, an acid gas regeneratorbottoms stream can be heated using the combined heated buffer fluid inan eighth heat exchanger with a thermal duty that can range betweenabout 45 MW and 55 MW (for example, 47.8 MW). The eighth heat exchangeris coupled to, in series with and is downstream of the set of first,second, third, fourth, and fifth heat exchangers relative to the flow ofbuffer fluid. The steam heat input for the acid gas regenerator can be 0MW because the alternative flow path disclosed in this configuration maysatisfy the entire heat load for the operation of the column. In analternative embodiment, the steam heat input for the acid gasregenerator can be reduced because the alternative flow path disclosedin this configuration may partially satisfy the heat load for theoperation of the column.

The combined heated buffer fluid branch exiting the eighth heatexchanger is flowed to the collection header or the buffer fluid tankfor reuse. In this manner, the sixth, the seventh and the eighth heatexchangers are coupled to, in series with each other relative to theflow of buffer fluid.

In some implementations, the heated buffer fluid can be flowed in seriesthrough the different plants. For example, the heated buffer fluid canbe flowed first to the sour water stripper plant and then to the benzeneextraction unit. In another implementation, within the benzeneextraction unit the heated buffer fluid stream may flow through the heatexchangers in a different order as presented. The heated buffer fluidexiting the eighth heat exchanger can be flowed to a buffer fluid tank.The buffer fluid from the buffer fluid tank can then be flowed to thedifferent plants to restart the waste heat recovery and reuse cycle.

Such recovery and reuse of waste heat indirectly from the hydrocrackingplant can result in decreasing or eliminating the heat energy forheating the sour water stripper plant, the aromatics complex orcombinations of them such as by about 62 MW.

Configuration 7

FIGS. 1BR-1BZ illustrate configurations and related scheme details forthermally integrating different refining plants in the crude oilrefining facility. The thermal integration described in theseconfigurations and illustrated in FIGS. 1BR-1BZ can reduce the crude oilrefining facility's energy consumption (for example, heating and coolingutilities). For example, a reduction in energy consumption by about 68MW, for example, 67.6 MW, translate to at least about 10%, for example,10.4%, of the energy consumption in the crude oil refining facility. Incertain schemes, a process stream (for example, a stream from onerefining sub-unit of an aromatics plant or other process streams) can beused to directly heat another process stream (for example, ahydrocracking plant stream or other process stream). In certainconfigurations, heat exchange between process streams can be implementedusing an intermediate buffer fluid, for example, water, oil, or otherbuffer fluid.

Configuration 7—Scheme A

In some implementations, multiple first streams in the multiple firstplants can be directly heated using multiple second streams in a secondplant. In some implementations, the multiple first plants can include asour water stripper plant, a sulfur recovery plant and an aromaticscomplex sub-unit including an aromatics complex benzene extraction unit.The second plant can include a hydrocracking plant.

FIG. 1BW shows a sour water stripper plant 710 in a crude oil refineryfacility. The sour water stripper bottoms stream can be flowed in theplant as a single stream and split into multiple streams or it can beflowed into the plant as multiple streams to facilitate heat recovery.

FIG. 1BZ shows a sulfur recovery plant 702 in a crude oil refineryfacility. The sour water stripper bottoms stream can be flowed in theplant as a single stream and split into multiple streams or it can beflowed into the plant as multiple streams to facilitate heat recovery.

FIGS. 1BR-1BV show a hydrocracking plant 712 in a crude oil refineryfacility. As shown in FIG. 1BR, a diesel product stream can directlyheat a first amine regenerator bottoms stream in a first heat exchangerwith a thermal duty that can range between about 5 MW and 15 MW (forexample, 10.4 MW). The transfer of heat directly to another processstreams captures heat that would have otherwise been discharged to theenvironment. The diesel product stream is returned to the hydrocrackingplant 712 for further processing.

As shown in FIG. 1BS, a second stage reaction section feed to a secondstage cold high pressure separator can directly heat a raffinatesplitter bottoms stream in a second heat exchanger with a thermal dutythat can range between about 5 MW and 15 MW (for example, 8.6 MW). Thetransfer of heat directly to another process streams captures heat thatwould have otherwise been discharged to the environment. The secondstage reaction section feed to a second stage cold high pressureseparator is returned to the hydrocracking plant 712 for furtherprocessing.

As shown in FIG. 1BT, a first stage reaction section first stage coldhigh pressure separator stream can directly heat a first sour waterstripper bottoms in a third heat exchanger with a thermal duty that canrange between about 15 MW and 25 MW (for example, 20.5 MW). The transferof heat directly to another process streams captures heat that wouldhave otherwise been discharged to the environment. The first stagereaction section first stage cold high pressure separator stream isreturned to the hydrocracking plant 712 for further processing.

As shown in FIG. 1BU (represented collectively by FIGS. 1BU-1 and 1BU-2)(specifically in FIG. 1BU-1), a product stripper overheads stream candirectly heat a second sour water stripper bottoms stream in a fourthheat exchanger with a thermal duty that can range between about 5 MW and15 MW (for example, 11.5 MW). The transfer of heat directly to anotherprocess streams captures heat that would have otherwise been dischargedto the environment. The product stripper overheads is returned to thehydrocracking plant 712 for further processing.

As shown specifically in FIG. 1BU-2, a kerosene pumparound stream candirectly heat a benzene column bottoms stream in a fifth heat exchangerwith a thermal duty that can range between about 1 MW and 10 MW (forexample, 6 MW). The transfer of heat directly to another process streamscaptures heat that would have otherwise been discharged to theenvironment. The kerosene pumparound stream is returned to thehydrocracking plant 712 for further processing.

As shown in FIG. 1BV an, a kerosene product stream in the hydrocrackingplant 712 can directly heat a second amine regenerator bottoms stream ina sixth heat exchanger with a thermal duty that can range between about5 MW and 15 MW (for example, 10.6 MW). The transfer of heat directly toanother process streams captures heat that would have otherwise beendischarged to the environment. The kerosene product stream is returnedto the hydrocracking plant 712 for further processing.

FIG. 1BY shows an aromatics complex benzene extraction unit 718 in acrude oil refining facility. The heated benzene column bottoms streamcan be flowed to the benzene extraction plant 718. The steam heat inputfor the benzene column can be 0 MW because the alternative flow pathdisclosed in this configuration may satisfy the entire heat load for theoperation of the column. In an alternative embodiment, the steam heatinput for the benzene column can be reduced because the alternative flowpath disclosed in this configuration may partially satisfy the heat loadfor the operation of the column.

FIG. 1BX also shows an aromatics complex benzene extraction unit 718.The heated raffinate splitter column bottom stream can be flowed to thebenzene extraction plant 718. The steam heat input for the raffinatesplitter can be 0 MW because the alternative flow path disclosed in thisconfiguration may satisfy the entire heat load for the operation of thecolumn. In an alternative embodiment, the steam heat input for theraffinate splitter can be reduced because the alternative flow pathdisclosed in this configuration may partially satisfy the heat load forthe operation of the column.

As shown in FIG. 1BZ, the two heated amine regenerator bottoms streamsare recombined and flowed to the sulfur recovery plant 702. In thismanner, the first heat exchanger and the sixth heat exchanger can becoupled to each other in parallel relative to the flow of amineregenerator bottoms. The steam heat input for the amine regenerator canbe 0 MW because the alternative flow path disclosed in thisconfiguration may satisfy the entire heat load for the operation of thecolumn. In an alternative embodiment, the steam heat input for the amineregenerator can be reduced because the alternative flow path disclosedin this configuration may partially satisfy the heat load for theoperation of the column.

As shown in FIG. 1BW, the two heated sour water stripper bottoms streamsare recombined and flowed to the sour water stripper plant 710. In thismanner, the third heat exchanger and the fourth heat exchanger can becoupled to each other in parallel relative to the flow of sour waterstripper bottoms. The steam heat input for the sour water stripper canbe 0 MW because the alternative flow path disclosed in thisconfiguration may satisfy the entire heat load for the operation of thecolumn. In an alternative embodiment, the steam heat input for the sourwater stripper can be reduced because the alternative flow pathdisclosed in this configuration may partially satisfy the heat load forthe operation of the column.

Such recovery and reuse of waste heat directly from the hydrocrackingplant can result in decreasing or eliminating the heat energy to heatthe aromatics complex, the sour water stripper plant, the sulfurrecovery plant or a combination of them, such as by about 68 MW.

Configuration 7—Scheme B

In some implementations, the multiple streams in the crude oil refiningfacility such as those present in the multiple first plants, such as inthe aromatics complex, the sour water stripper plant and the sulfurrecovery plant, can be indirectly heated using the multiple secondstreams in a second plant, such as one or more hydrocracking plant, asheat energy sources.

Indirectly heating the streams can include heating the streams through abuffer fluid, for example, oil, water, or other buffer fluid. A bufferfluid (for example, high pressure water) from a buffer fluid tank (forexample, hot water tank) is flowed to the hydrocracking plant 712. Thebuffer fluid can be flowed into the plant as a single stream and splitinto multiple streams or it can be flowed into the plant as multiplestreams.

To do so, one or more buffer fluid streams (for example, oil, water orother buffer fluid) can be heated using streams in the hydrocrackingplant 712 using respective heat exchangers. The heated buffer fluids canbe collected in a buffer fluid collection header. Streams in the sourwater stripper plant 710, the sulfur recovery plant 702 and the benzeneextraction plant 718 can be heated using the heated buffer fluid inrespective heat exchangers. The heated buffer fluid exiting the heatexchangers can be flowed to a buffer fluid tank. The buffer fluid fromthe buffer fluid tank can then be flowed to the aromatics plant torestart the waste heat recovery and reuse cycle.

Configuration 8

FIGS. 1CA-1CJ illustrate configurations and related scheme details forthermally integrating different refining plants in the crude oilrefining facility. The thermal integration described in theseconfigurations and illustrated in FIGS. 1CA-1CJ can reduce the crude oilrefining facility's energy consumption (for example, heating and coolingutilities). For example, a reduction in energy consumption by about 73MW, for example, 73.1 MW, can translate to at least about 12%, forexample, 11.2%, of the energy consumption in the crude oil refiningfacility. In certain schemes, a process stream (for example, a streamfrom one refining sub-unit of an aromatics plant or other processstreams) can be used to directly heat another process stream (forexample, a hydrocracking plant stream or other process stream). Incertain configurations, heat exchange between process streams can beimplemented using an intermediate buffer fluid, for example, water, oil,or other buffer fluid.

Configuration 8—Scheme A

In some implementations, multiple first streams in the multiple firstplants can be directly heated using multiple second streams in thesecond plant. In some implementations, the multiple first plants caninclude a naphtha hydrotreating plant, a sour water stripper plant, agas separation plant and an aromatics complex sub-unit including anaromatic complex benzene extraction unit. The second plant can include ahydrocracking plant 712.

FIG. 1CF shows a naphtha hydrotreating plant 714 in a crude oil refineryfacility. The naphtha splitter bottoms stream can be flowed in the plantas a single stream and split into multiple streams or it can be flowedinto the plant as multiple streams to facilitate heat recovery.

FIG. 1CG shows a sour water stripper plant 710 in a crude oil refineryfacility. The sour water stripper bottoms stream can be flowed in theplant as a single stream and split into multiple streams or it can beflowed into the plant as multiple streams to facilitate heat recovery.

FIG. 1CJ shows a gas separation plant 704 in a crude oil refineryfacility. The C3/C4 splitter bottoms stream can be flowed in the plantas a single stream and split into multiple streams or it can be flowedinto the plant as multiple streams to facilitate heat recovery.

FIGS. 1CA-10E show a hydrocracking plant 712 in a crude oil refineryfacility. As shown in FIG. 1CA, a diesel product stream can directlyheat a first naphtha splitter bottoms stream in a first heat exchangerwith a thermal duty that can range between about 5 MW and 10 MW (forexample, 6.6 MW). The diesel product stream can also directly heat afirst C3/C4 splitter bottoms stream in a second heat exchanger with athermal duty that can range between about 1 MW and 10 MW (for example,4.9 MW). For both streams, the transfer of heat directly to anotherprocess streams captures heat that would have otherwise been dischargedto the environment. In an alternative embodiment, the coolingrequirement of the diesel product stream can be 0 MW because thealternative flow path disclosed in this configuration may satisfy theentire cooling requirement for the diesel product stream. The dieselproduct stream is returned to the hydrocracking plant 712 for furtherprocessing.

As shown in FIG. 1CA, the second heat exchanger is coupled to, in serieswith and is downstream of the first heat exchanger relative to the flowof the diesel product stream. In some implementations, the dieselproduct stream can be flowed in series through the different plants. Forexample, the diesel product stream is flowed first through the gasseparation plant heat exchanger and then through the naphthahydrotreating plant heat exchanger.

As shown in FIG. 1CB, a second reaction section feed stream to secondstage cold high pressure separator can directly heat a raffinatesplitter bottoms stream in a third heat exchanger with a thermal dutythat can range between about 5 MW and 15 MW (for example, 8.6 MW). Thetransfer of heat directly to another process streams captures heat thatwould have otherwise been discharged to the environment. The secondreaction section feed to second stage cold high pressure separator isreturned to the hydrocracking plant 712 for further processing.

As shown in FIG. 1CC, a first reaction section feed stream to a firststage cold high pressure separator in the hydrocracking plant 712 candirectly heat a first sour water stripper bottoms stream in a fourthheat exchanger with a thermal duty that can range between about 15 MWand 25 MW (for example, 20.5 MW). The transfer of heat directly toanother process streams captures heat that would have otherwise beendischarged to the environment. The first reaction section feed stream toa first stage cold high pressure separator is returned to thehydrocracking plant 712 for further processing.

As shown in FIG. 1CD (represented collectively by FIGS. 1CD-1 and 1CD-2)(specifically FIG. 1CD-1), a product stripper overheads stream candirectly heat a second sour water stripper bottoms stream in a fifthheat exchanger with a thermal duty that can range between about 5 MW and15 MW (for example, 11.5 MW). The transfer of heat directly to anotherprocess streams captures heat that would have otherwise been dischargedto the environment. The product stripper overheads stream is returned tothe hydrocracking plant 712 for further processing.

As shown specifically in FIG. 1CD-2, the kerosene pumparound stream candirectly heat a second naphtha splitter bottoms stream in a sixth heatexchanger with a thermal duty that can range between about 1 MW and 10MW (for example, 5.7 MW). The kerosene pumparound stream can alsodirectly heat a de-ethanizer bottoms stream in a seventh heat exchangerwith a thermal duty that can range between about 1 MW and 10 MW (forexample, 4.3 MW). For both streams, the transfer of heat directly toanother process streams captures heat that would have otherwise beendischarged to the environment. In an alternative embodiment, the coolingrequirement of the kerosene pumparound stream can be 0 MW because thealternative flow path disclosed in this configuration may satisfy theentire cooling requirement for the kerosene pumparound stream for theoperation of the fractionator column. The kerosene pumparound stream isreturned to the hydrocracking plant 712 for further processing.

As shown in FIG. 1CD, the seventh heat exchanger is coupled to, inseries with and is downstream of the sixth heat exchanger relative tothe flow of kerosene pumparound stream. In some implementations, thekerosene pumparound stream can be flowed in series through the differentplants. For example, the kerosene pumparound stream is flowed firstthrough the de-ethanizer heat exchanger and then through the naphthasplitter heat exchanger.

As shown in FIG. 1CE, the kerosene product stream can directly heat abenzene column bottoms stream in an eighth heat exchanger with a thermalduty that can range between about 1 MW and 10 MW (for example, 6 MW).The kerosene product stream can also directly heat a second C3/C4splitter bottom stream in a ninth heat exchanger with a thermal dutythat can range between about 1 MW and 10 MW (for example, 5 MW). Forboth streams, the transfer of heat directly to another process streamscaptures heat that would have otherwise been discharged to theenvironment. The kerosene product stream is returned to thehydrocracking plant 712 for further processing.

As shown in FIG. 1CE, the ninth heat exchanger is coupled to, in serieswith and is downstream of the eighth heat exchanger relative to the flowof kerosene product stream. In some implementations, the keroseneproduct stream can be flowed in series through the different plants. Forexample, the kerosene product stream is flowed first through the C3/C4splitter heat exchanger and then through the benzene column heatexchanger.

FIG. 1CI shows an aromatics complex benzene extraction unit 718 in acrude oil refining facility. The heated benzene column bottoms streamcan be flowed to the benzene extraction unit 718. The steam heat inputfor the benzene column can be 0 MW because the alternative flow pathdisclosed in this configuration may satisfy the entire heat load for theoperation of the column. In an alternative embodiment, the steam heatinput for the benzene column can be reduced because the alternative flowpath disclosed in this configuration may partially satisfy the heat loadfor the operation of the column.

FIG. 1CH also shows an aromatics complex benzene extraction unit 718.The heated raffinate splitter column bottoms stream can be flowed to thebenzene extraction unit 718. The steam heat input for the raffinatesplitter can be 0 MW because the alternative flow path disclosed in thisconfiguration may satisfy the entire heat load for the operation of thecolumn. In an alternative embodiment, the steam heat input for theraffinate splitter can be reduced because the alternative flow pathdisclosed in this configuration may partially satisfy the heat load forthe operation of the column.

As shown in FIG. 1CF, the two naphtha splitter bottoms streams arerecombined and can be flowed to the naphtha hydro-treating plant 714. Inthis manner, the first and the sixth heat exchangers can be coupled toeach other in parallel relative to the flow of naphtha splitter bottoms.The steam heat input for the naphtha splitter can be 0 MW because thealternative flow path disclosed in this configuration may satisfy theentire heat load for the operation of the column. In an alternativeembodiment, the steam heat input for the naphtha splitter can be reducedbecause the alternative flow path disclosed in this configuration maypartially satisfy the heat load for the operation of the column.

As shown in FIG. 1CG, the two sour water stripper bottoms streams arerecombined and can be flowed to the sour water stripper plant 710. Inthis manner, the fourth heat exchanger and the fifth heat exchanger canbe coupled to each other in parallel relative to the flow of sour waterstripper bottoms. The steam heat input for the sour water stripper canbe 0 MW because the alternative flow path disclosed in thisconfiguration may satisfy the entire heat load for the operation of thecolumn. In an alternative embodiment, the steam heat input for the sourwater stripper can be reduced because the alternative flow pathdisclosed in this configuration may partially satisfy the heat load forthe operation of the column.

As shown in FIG. 1CJ, the two C3/C4 splitter bottoms streams arerecombined and can be flowed to the gas separation plant 704. In thismanner, the second heat exchanger and the ninth heat exchanger can becoupled to each other in parallel relative to the flow of C3/C4 splitterbottoms. The steam heat input for the C3/C4 splitter can be 0 MW becausethe alternative flow path disclosed in this configuration may satisfythe entire heat load for the operation of the column. In an alternativeembodiment, the steam heat input for the C3/C4 splitter can be reducedbecause the alternative flow path disclosed in this configuration maypartially satisfy the heat load for the operation of the column.

As shown in FIG. 1CJ, the heated de-ethanizer bottoms stream can also beflowed to the gas separation plant 704. The steam heat input for thede-ethanizer column can be 0 MW because the alternative flow pathdisclosed in this configuration may satisfy the entire heat load for theoperation of the column. In an alternative embodiment, the steam heatinput for the de-ethanizer column can be reduced because the alternativeflow path disclosed in this configuration may partially satisfy the heatload for the operation of the column.

Such recovery and reuse of waste heat directly from the hydrocrackingplant can result in decreasing or eliminating the heat energy to heatthe gas separation plant, an amine regeneration plant, the aromaticscomplex or a combinations of them such as by about 73 MW.

Configuration 8—Scheme B

In some implementations, the multiple streams in the crude oil refiningfacility such as those present in the aromatic complex, the sour waterstripper plant, the sulfur recovery plant can be indirectly heated usinga buffer fluid, for example, oil, water or other buffer fluid, using themultiple second streams in the hydrocracking plant as heat energysources.

Indirectly heating the streams can include heating the streams through abuffer fluid, for example, oil, water, or other buffer fluid. A bufferfluid (for example, high pressure water) from a buffer fluid tank (forexample, hot water tank) is flowed to the hydrocracking plant 712. Thebuffer fluid can be flowed into the plant as a single stream and splitinto multiple streams or it can be flowed into the plant as multiplestreams.

To do so, one or more buffer fluid stream (for example, oil, water orother buffer fluid) can be heated using streams in the hydrocrackingplant using respective heat exchangers. The heated buffer fluids can becollected in a buffer fluid collection header. Streams in the naphthahydro-treating plant 714, the sour water stripper plant 710, and thearomatic complex benzene extraction plant 718 can be heated using theheated buffer fluid streamsin respective heat exchangers. The heatedbuffer fluid exiting the heat exchangers can be flowed to a buffer fluidtank. The buffer fluid from the buffer fluid tank can then be flowed tothe aromatics plant to restart the waste heat recovery and reuse cycle.

Configuration 9

FIGS. 1CK-1CT illustrate configurations and related scheme details forthermally integrating different refining plants in the crude oilrefining facility. The thermal integration described in theseconfigurations and illustrated in FIGS. 1CK-1CT can reduce the crude oilrefining facility's energy consumption (for example, heating and coolingutilities). For example, a reduction in energy consumption by about 83MW, for example, 83.4 MW, can translate to at least about 12%, forexample, 12.8%, of the energy consumption in the crude oil refiningfacility. In certain schemes, a process stream (for example, a streamfrom one refining sub-unit of an aromatics plant or other processstreams) can be used to directly heat another process stream (forexample, a hydrocracking plant stream or other process stream). Incertain configurations, heat exchange between process streams can beimplemented using an intermediate buffer fluid, for example, water, oil,or other buffer fluid.

Configuration 9—Scheme A

In some implementations, multiple first streams in the multiple firstplants can be directly heated using multiple second streams in themultiple second plants. In some implementations, the multiple firstplants can include an amine regeneration plant, a sulfur recovery plantand an aromatic complex sub-unit including an aromatic complex benzeneextraction plant. The multiple second plants can include a hydrocrackingplant and a diesel hydro-treating plant. In some implementations, one ofthe first multiple plants is directly heated by all of the multiplesecond plants and one of the second multiple plants directly heats onlyone of the first multiple plants. In such an instance, the one firstmultiple plant is the amine regeneration plant and the one secondmultiple plant is the diesel hydrotreating plant.

FIG. 1CQ shows sulfur recovery plant 702 in a crude oil refineryfacility. The amine regenerator bottoms stream can be flowed in theplant as a single stream and split into multiple streams or it can beflowed into the plant as multiple streams to facilitate heat recovery.

FIG. 1CT shows an amine regeneration plant 706 in a crude oil refineryfacility. The acid gas regenerator bottoms stream can be flowed in theplant as a single stream and split into multiple streams or it can beflowed into the plant as multiple streams to facilitate heat recovery.

FIGS. 1BC-1BF show a hydrocracking plant 712 in a crude oil refineryfacility. As shown in FIG. 1CK, a diesel product stream can directlyheat a first amine regenerator bottoms stream in a first heat exchangerwith a thermal duty that can range between about 5 MW and 15 MW (forexample, 10.4 MW). The transfer of heat directly to another processstreams captures heat that would have otherwise been discharged to theenvironment. The diesel product stream is returned to the hydrocrackingplant 712 for further processing.

As shown in FIG. 1CL, a second reaction section feed stream to secondstage cold high pressure separator can directly heat a raffinatesplitter bottoms stream in a second heat exchanger with a thermal dutythat can range between about 5 MW and 15 MW (for example, 8.6 MW). Thetransfer of heat directly to another process streams captures heat thatwould have otherwise been discharged to the environment. The secondreaction section feed stream to second stage cold high pressureseparator is returned to the hydrocracking plant 712 for furtherprocessing.

As shown in FIG. 1CM, a first stage cold high pressure separator feedcan directly heat a first acid gas regenerator feed stream in a thirdheat exchanger with a thermal duty that can range between about 25 MWand 35 MW (for example, 27.9 MW). The transfer of heat directly toanother process streams captures heat that would have otherwise beendischarged to the environment. The first stage cold high pressureseparator feed is returned to the hydrocracking plant 712 for furtherprocessing.

As shown in FIG. 1CN (represented collectively by FIGS. 1CN-1 and 1CN-2)(specifically FIG. 1CN-2), a kerosene pumparound stream can directlyheat a benzene column bottoms stream in a fourth heat exchanger with athermal duty that can range between about 1 MW and 10 MW (for example, 6MW). The transfer of heat directly to another process streams capturesheat that would have otherwise been discharged to the environment. Thekerosene pumparound stream is returned to the hydrocracking plant 712for further processing.

As shown in FIG. 1CO, a kerosene product stream can directly heat asecond amine regenerator bottoms branch in a fifth heat exchanger with athermal duty that can range between about 5 MW and 15 MW (for example,10.6 MW). The transfer of heat directly to another process streamscaptures heat that would have otherwise been discharged to theenvironment. The kerosene product stream is returned to thehydrocracking plant 712 for further processing.

FIG. 1CP shows a diesel hydrotreating plant 700 in a crude oil refineryfacility. As shown in FIG. 1CP, a diesel stripper bottoms stream in candirectly heat a second acid gas regenerator bottoms stream in a sixthheat exchanger with a thermal duty that can range between about 15 MWand 25 MW (for example, 19.9 MW). The diesel stripper bottoms stream isreturned to the hydrocracking plant 712 for further processing.

FIG. 1CS shows an aromatics complex benzene extraction unit 718 in acrude oil refining facility. The heated benzene column bottoms streamcan be flowed to the benzene extraction plant 718. The steam heat inputfor the benzene column can be 0 MW because the alternative flow pathdisclosed in this configuration may satisfy the entire heat load for theoperation of the column. In an alternative embodiment, the steam heatinput for the benzene column can be reduced because the alternative flowpath disclosed in this configuration may partially satisfy the heat loadfor the operation of the column.

FIG. 1CR also shows an aromatics complex benzene extraction unit 718.The heated raffinate splitter column bottoms stream can be flowed to thebenzene extraction plant 718 in the aromatics complex. The steam heatinput for the raffinate splitter can be 0 MW because the alternativeflow path disclosed in this configuration may satisfy the entire heatload for the operation of the column. In an alternative embodiment, thesteam heat input for the raffinate splitter can be reduced because thealternative flow path disclosed in this configuration may partiallysatisfy the heat load for the operation of the column.

As shown in FIG. 1CQ, the two amine regenerator bottoms streams arerecombined and can be flowed to the sulfur recovery plant 702. In thismanner, the first and the fifth heat exchangers can be coupled to eachother in parallel relative to the flow of amine regenerator bottoms. Thesteam heat input for the amine regenerator can be 0 MW because thealternative flow path disclosed in this configuration may satisfy theentire heat load for the operation of the column. In an alternativeembodiment, the steam heat input for the amine regenerator can bereduced because the alternative flow path disclosed in thisconfiguration may partially satisfy the heat load for the operation ofthe column. In this configuration, only the hydrocracking plant 712provides energy to the sulfur recovery plant 702.

As shown in FIG. 1CT, the two acid gas regenerator bottoms streams arerecombined and can be flowed to the amine regeneration plant 706. Inthis manner, the third and the sixth heat exchangers can be coupled toeach other in parallel relative to the flow of acid gas regeneratorbottoms. The steam heat input for the acid gas regenerator can be 0 MWbecause the alternative flow path disclosed in this configuration maysatisfy the entire heat load for the operation of the column. In analternative embodiment, the steam heat input for the acid gasregenerator can be reduced because the alternative flow path disclosedin this configuration may partially satisfy the heat load for theoperation of the column. In this configuration, the hydrocracking plant712 and the diesel hydrotreating plant 700 provide energy to the amineregeneration plant 706.

Such recovery and reuse of waste heat directly from both thehydrocracking and the diesel hydrotreating plants can result indecreasing or eliminating the heat energy to heat the aromatic complex,sulfur recovery plant, an amine regeneration plant or a combination ofthem such as by about 83 MW.

Configuration 9—Scheme B

In some implementations, the multiple streams in the crude oil refiningfacility such as those present in the aromatic complex, sulfur recoveryplant, and the amine regeneration plant can be indirectly heated using abuffer fluid, for example, oil, water or other buffer fluid, using themultiple second streams in hydrocracking plant or diesel hydrotreatingplant as heat energy sources.

Indirectly heating the streams can include heating the streams through abuffer fluid, for example, oil, water, or other buffer fluid. A bufferfluid (for example, high pressure water) from a buffer fluid tank (forexample, hot water tank) is flowed to the hydrocracking plant 712 andthe diesel hydrotreating plant 700. The buffer fluid can be flowed intoeach plant as a single stream and split into multiple streams or it canbe flowed into the plant as multiple streams.

To do so, the one or more buffer fluid streams (for example, oil, wateror other buffer fluid) can be heated using streams in the hydrocrackingplant 712 and the diesel hydro-treating plant 700 using respective heatexchangers. The heated buffer fluids can be collected in a buffer fluidcollection header. Streams in the sulfur recovery plant 702, the amineregenerator plant 706, and the aromatic complex benzene extraction plant718 can be heated using the heated buffer fluid streams in respectiveheat exchangers. The heated buffer fluid exiting the heat exchangers canbe flowed to a buffer fluid tank. The buffer fluid from the buffer fluidtank can then be flowed to the aromatics plant to restart the waste heatrecovery and reuse cycle.

Configuration 10

FIGS. 1CU-1DF illustrate configurations and related scheme details forthermally integrating different refining plants in the crude oilrefining facility. The thermal integration described in theseconfigurations and illustrated in FIGS. 1CU-1DF can reduce the crude oilrefining facility's energy consumption (for example, heating and coolingutilities) by about 115 MW, which translates to at least about 17% ofthe energy consumption in the crude oil refining facility. In certainschemes, a process stream (for example, a stream from one refiningsub-unit of an aromatics plant or other process streams) can be used todirectly heat another process stream (for example, a hydrocracking plantstream or other process stream). In certain configurations, heatexchange between process streams can be implemented using anintermediate buffer fluid, for example, water, oil, or other bufferfluid.

Configuration 10—Scheme A

In some implementations, multiple first streams in the multiple firstplants can be directly heated using multiple second streams in themultiple second plants. In some implementations, the multiple firstplants can include amine regeneration plant, a sulfur recovery plant, asour water stripper plant 710, and an aromatics complex sub-unitincluding an aromatic complex benzene extraction plant. The multiplesecond plants can include a hydrocracking plant, a natural gas steamreforming hydrogen plant and a diesel hydrotreating plant. In someimplementations, one of the first multiple plants is directly heated byall of the multiple second plants and one of the second multiple plantsdirectly heats only one of the first multiple plants. In such aninstance, the one first multiple plant is the sour water stripper plantand the one second multiple plants is the natural gas steam reforminghydrogen plant. In some implementations, one of the first multipleplants is directly heated by two of the multiple second plants. In suchan instance, the one of the first multiple plants is the amineregeneration plant and the two of the multiple second plants are thehydrocracking plant and the diesel hydrotreating plant.

FIG. 1DB shows sulfur recovery plant 702 in a crude oil refineryfacility. The amine regenerator bottoms stream can be flowed in theplant as a single stream and split into multiple streams or it can beflowed into the plant as multiple streams to facilitate heat recovery.

FIG. 1DE shows an amine regeneration plant 706 in a crude oil refineryfacility. The acid gas regenerator bottoms stream can be flowed in theplant as a single stream and split into multiple streams or it can beflowed into the plant as multiple streams to facilitate heat recovery.

FIG. 1DF shows a sour water stripper plant 710 in a crude oil refineryfacility. The sour water stripper bottoms stream can be flowed in theplant as a single stream and split into multiple streams or it can beflowed into the plant as multiple streams to facilitate heat recovery.

FIGS. 1CU-1CY show a hydrocracking plant 712 in a crude oil refineryfacility. As shown in FIG. 1CU, a diesel product stream can directlyheat a first amine regenerator bottoms stream in a first heat exchangerwith a thermal duty that can range between about 5 MW and 15 MW (forexample, 10.4 MW). The transfer of heat directly to another processstreams captures heat that would have otherwise been discharged to theenvironment. The diesel product stream is returned to the hydrocrackingplant 712 for further processing.

As shown in FIG. 1CV, a second reaction section feed stream to secondstage cold high pressure separator can directly heat a raffinatesplitter bottoms stream in a second heat exchanger with a thermal dutythat can range between about 5 MW and 15 MW (for example, 8.6 MW). Thetransfer of heat directly to another process streams captures heat thatwould have otherwise been discharged to the environment. The secondreaction section feed stream to second stage cold high pressureseparator is returned to the hydrocracking plant 712 for furtherprocessing.

As shown in FIG. 1CW, a first stage cold high pressure separator feedcan directly heat a first acid gas regenerator bottom stream in a thirdheat exchanger with a thermal duty that can range between about 25 MWand 35 MW (for example, 27.9 MW). The transfer of heat directly toanother process streams captures heat that would have otherwise beendischarged to the environment. The first stage cold high pressureseparator feed is returned to the hydrocracking plant 712 for furtherprocessing.

As shown in FIG. 1CX (represented collectively by FIGS. 1CX-1 and 1CX-2)(specifically FIG. 1CX-1), a product stripper overhead stream candirectly heat a first sour water stripper bottoms branch in a fourthheat exchanger with a thermal duty that can range between about 5 MW and15 MW (for example, 11.8 MW). The transfer of heat directly to anotherprocess streams captures heat that would have otherwise been dischargedto the environment. The product stripper overhead stream is returned tothe hydrocracking plant 712 for further processing.

As shown specifically in FIG. 1CX-2, a kerosene pumparound stream candirectly heat a benzene column bottoms stream in a fifth heat exchangerwith a thermal duty that can range between about 1 MW and 10 MW (forexample, 6 MW). The transfer of heat directly to another process streamscaptures heat that would have otherwise been discharged to theenvironment. The kerosene pumparound stream is returned to thehydrocracking plant 712 for further processing.

As shown in FIG. 1CY, a kerosene product stream can directly heat asecond amine regenerator bottoms stream in a sixth heat exchanger with athermal duty that can range between about 5 MW and 15 MW (for example,10.6 MW). The transfer of heat directly to another process streamscaptures heat that would have otherwise been discharged to theenvironment. The kerosene product stream is returned to thehydrocracking plant 712 for further processing.

FIG. 1CZ shows a diesel hydrotreating plant 700 in a crude oil refineryfacility. A diesel stripper overheads stream can directly heat a secondsour water stripper bottoms branch in a seventh heat exchanger with athermal duty that can range between about 10 MW and 20 MW (for example,15.9 MW). The transfer of heat directly to another process streamscaptures heat that would have otherwise been discharged to theenvironment. The diesel stripper overheads is returned to the dieselhydrotreating plant 700 for further processing.

Also shown in FIG. 1CZ, a diesel stripper bottoms stream can directlyheat a second acid gas regenerator bottoms stream in an eighth heatexchanger with a thermal duty that can range between about 15 MW and 25MW (for example, 19.9 MW). The transfer of heat directly to anotherprocess streams captures heat that would have otherwise been dischargedto the environment. The diesel stripper bottoms stream is returned tothe diesel hydro-treating plant 700 for further processing.

FIG. 1DA shows a natural gas steam reforming hydrogen plant 708 in acrude oil refinery facility. A low temperature shift (LTS) converterproduct steam can directly heat a third sour water stripper bottomsstream in a ninth heat exchanger with a thermal duty that can rangebetween about 1 MW and 10 MW (for example, 4.3 MW). The transfer of heatdirectly to another process streams captures heat that would haveotherwise been discharged to the environment. The LTS converter productsteam is returned to the hydrogen plant 708 for further processing.

FIG. 1DD shows an aromatics complex benzene extraction unit 718 in acrude oil refining facility. The heated benzene column bottom stream canbe flowed to the benzene extraction unit 718. The steam heat input forthe benzene column can be 0 MW because the alternative flow pathdisclosed in this configuration may satisfy the entire heat load for theoperation of the column. In an alternative embodiment, the steam heatinput for the benzene column can be reduced because the alternative flowpath disclosed in this configuration may partially satisfy the heat loadfor the operation of the column.

FIG. 1DC also shows an aromatics complex benzene extraction unit 718.The heated raffinate splitter column bottom stream can be flowed to thebenzene extraction unit 718. The steam heat input for the raffinatesplitter can be 0 MW because the alternative flow path disclosed in thisconfiguration may satisfy the entire heat load for the operation of thecolumn. In an alternative embodiment, the steam heat input for theraffinate splitter can be reduced because the alternative flow pathdisclosed in this configuration may partially satisfy the heat load forthe operation of the column.

As shown in FIG. 1DF, the three streams of the sour water stripperbottoms are recombined and flowed to the sour water stripper plant 710.In this manner, the fourth heat exchanger, the seventh heat exchangerand the ninth exchanger can be coupled to each other in parallelrelative to the flow of sour water stripper bottoms. The steam heatinput for the sour water stripper can be 0 MW because the alternativeflow path disclosed in this configuration may satisfy the entire heatload for the operation of the column. In an alternative embodiment, thesteam heat input for the sour water stripper can be reduced because thealternative flow path disclosed in this configuration may partiallysatisfy the heat load for the operation of the column. In thisconfiguration, the hydrocracking plant 712, the diesel hydrotreatingplant 700, and the natural gas steam reforming hydrogen plant 708provide energy to the sour water stripper plant 710.

As shown in FIG. 1DB, the two streams of the amine regenerator bottomsare recombined and flowed to the sulfur recovery plant 702. In thismanner, the first heat exchanger and the sixth heat exchanger can becoupled to each other in parallel relative to the flow of amineregenerator bottoms. The steam heat input for the amine regenerator canbe 0 MW because the alternative flow path disclosed in thisconfiguration may satisfy the entire heat load for the operation of thecolumn. In an alternative embodiment, the steam heat input for the amineregenerator can be reduced because the alternative flow path disclosedin this configuration may partially satisfy the heat load for theoperation of the column. In this configuration, only the hydrocrackingplant 712 provide energy to the sulfur recovery plant 702.

As shown in FIG. 1DE, the two streams of the acid gas regeneratorbottoms are recombined and flowed to the amine regeneration plant 706.In this manner, the third and the eighth heat exchangers can be coupledto each other in parallel relative to the flow of acid gas regeneratorbottoms. The steam heat input for the acid gas regenerator can be 0 MWbecause the alternative flow path disclosed in this configuration maysatisfy the entire heat load for the operation of the column. In analternative embodiment, the steam heat input for the acid gasregenerator can be reduced because the alternative flow path disclosedin this configuration may partially satisfy the heat load for theoperation of the column. In this configuration, both the hydrocrackingplant 712 and diesel hydrotreating plant 700 provide energy to the amineregeneration plant 706.

Such recovery and reuse of waste heat directly from the hydrocracking,the diesel hydrotreating, and the natural gas steam reforming hydrogenplants can result in decreasing or eliminating the heat energy to heatthe aromatics complex, the sour water stripper plant, the sulfurrecovery plant, the amine regeneration plant or a combination of them,such as by about 115 MW.

Configuration 10—Scheme B

In some implementations, the multiple streams in the crude oil refiningfacility such as those present in the aromatic complex, the sour waterstripper plant, the sulfur recovery plant, the amine regeneration plantcan be indirectly heated using a buffer fluid, for example, oil, wateror other buffer fluid, using the multiple second streams inhydrocracking plant, the diesel hydrotreating plant, the natural gassteam reforming hydrogen plant, or combinations thereof, as heat energysources

Indirectly heating the streams can include heating the streams through abuffer fluid, for example, oil, water, or other buffer fluid. A bufferfluid (for example, high pressure water) from a buffer fluid tank (forexample, hot water tank) is flowed to the hydrocracking plant 712, thediesel hydrotreating plant 700 and natural gas steam reforming hydrogenplant 708. The buffer fluid can be flowed into each plant as a singlestream and split into multiple streams or it can be flowed into theplant as multiple streams.

To do so, the one or more buffer fluid streams (for example, oil, wateror other buffer fluid) can be heated using streams in the hydrocrackingplant 712, the diesel hydro-treating plant 700, and the hydrogen plant708 using respective heat exchangers. The heated buffer fluids can becollected in a buffer fluid collection header. Streams in the aromaticcomplex benzene extraction plant 718, the sour water stripper plant 702,the sulfur recovery plant 702, and the amine regeneration plant 706 canbe heated using the heated buffer fluid streams in respective heatexchangers. The heated buffer fluid exiting the heat exchangers can beflowed to a buffer fluid tank. The buffer fluid from the buffer fluidtank can then be flowed to the aromatics plant to restart the waste heatrecovery and reuse cycle.

Configuration 11

FIGS. 1DG-1DS illustrate configurations and related scheme details forthermally integrating different refining plants in the crude oilrefining facility. The thermal integration described in theseconfigurations and illustrated in FIGS. 1DG-1DS can reduce the crude oilrefining facility's energy consumption (for example, heating and coolingutilities). For example, a reduction in energy consumption by about 130MW can translate to at least about 20% of the energy consumption in thecrude oil refining facility. In certain schemes, a process stream (forexample, a stream from one refining sub-unit of an aromatics plant orother process streams) can be used to directly heat another processstream (for example, a hydrocracking plant stream or other processstream). In certain configurations, heat exchange between processstreams can be implemented using an intermediate buffer fluid, forexample, water, oil, or other buffer fluid.

Configuration 11—Scheme A

In some implementations, multiple first streams in the multiple firstplants can be directly heated using multiple second streams in themultiple second plants In some implementations, the multiple firstplants can include an amine regeneration plant, a sulfur recovery plant,a gas separation plant, a sour water stripper plant, and an aromaticscomplex including an aromatics benzene extraction unit. The multiplesecond plants can include a hydrocracking plant, a natural gas steamreforming hydrogen plant and a diesel hydro-treating plant. In someimplementations, one of the first multiple plants is directly heated byall of the multiple second plants and one of the second multiple plantsdirectly heats only one of the first multiple plants. In such aninstance, the one first multiple plant is the sour water stripper plantand the one second multiple plants is the natural gas steam reforminghydrogen plant. In some implementations, two of the first multipleplants are directly heated by the same two of the multiple secondplants. In such an instance, the two of the first multiple plants is theamine regeneration plant and the gas separation plant and the same twoof the multiple second plants are the hydrocracking plant and the dieselhydrotreating plant.

FIG. 1DN shows sulfur recovery plant 702 in a crude oil refineryfacility. The amine regenerator bottoms stream can be flowed in theplant as a single stream and split into multiple streams or it can beflowed into the plant as multiple streams to facilitate heat recovery.

FIG. 1DQ shows an amine regeneration plant 706 in a crude oil refineryfacility. The acid gas regenerator bottoms stream can be flowed in theplant as a single stream and split into multiple streams or it can beflowed into the plant as multiple streams to facilitate heat recovery.

FIG. 1DR shows a sour water stripper plant 710 in a crude oil refineryfacility. The sour water stripper bottoms stream can be flowed in theplant as a single stream and split into multiple streams or it can beflowed into the plant as multiple streams to facilitate heat recovery.

FIG. 1DS shows a gas separation plant 704 in a crude oil refineryfacility. The C3/C4 splitter bottoms stream can be flowed in the plantas a single stream and split into multiple streams or it can be flowedinto the plant as multiple streams to facilitate heat recovery.

As shown in FIG. 1DG, a diesel product stream in can directly heat afirst amine regenerator bottoms stream in a first heat exchanger with athermal duty that can range between about 5 MW and 15 MW (for example,10.4 MW). The transfer of heat directly to another process streamscaptures heat that would have otherwise been discharged to theenvironment. The diesel product stream is returned to the hydrocrackingplant 712 for further processing.

As shown in FIG. 1DH, a second reaction section feed stream to secondstage cold high pressure separator can directly heat a raffinatesplitter bottoms stream in a second heat exchanger with a thermal dutythat can range between about 5 MW and 15 MW (for example, 8.6 MW). Thetransfer of heat directly to another process streams captures heat thatwould have otherwise been discharged to the environment. The secondreaction section feed stream to second stage cold high pressureseparator is returned to the hydrocracking plant 712 for furtherprocessing.

As shown in FIG. 1DI, a first stage cold high pressure separator streamcan directly heat a first acid gas regenerator bottoms stream in a thirdheat exchanger with a thermal duty that can range between about 25 MWand 35 MW (for example, 27.9 MW). The transfer of heat directly toanother process streams captures heat that would have otherwise beendischarged to the environment. The first stage cold high pressureseparator stream is returned to the hydrocracking plant 712 for furtherprocessing.

As shown in FIG. 1DJ (represented collectively by FIGS. 1DJ-1 and 1DJ-2)(specifically FIG. 1DJ-1), a product stripper overheads stream candirectly heat a first sour water stripper bottoms stream in a fourthheat exchanger with a thermal duty that can range between about 5 MW and15 MW (for example, 11.8 MW). The transfer of heat directly to anotherprocess streams captures heat that would have otherwise been dischargedto the environment. The product stripper overhead stream is returned tothe hydrocracking plant 712 for further processing.

As specifically shown in FIG. 1DJ-2, a kerosene pumparound stream in thehydrocracking plant can directly heat a benzene column bottoms stream ina fifth heat exchanger with a thermal duty that can range between about1 MW and 10 MW (for example, 6 MW). The kerosene pumparound stream canalso directly heat a first C3/C4 stripper bottoms stream in a sixth heatexchanger with a thermal duty that can range between about 1 MW and 10MW (for example, 4.2 MW). For both streams, the transfer of heatdirectly to another process streams captures heat that would haveotherwise been discharged to the environment. In this configuration thecooling requirement of the kerosene pumparound stream can be 0 MWbecause the alternative flow path disclosed in this configuration maysatisfy the entire cooling requirement for the kerosene pumparoundstream for the operation of the fractionator column. The kerosenepumparound stream is returned to the hydrocracking plant 712 for furtherprocessing.

As shown in FIG. 1DJ-2, the sixth heat exchanger is coupled to, inseries with and is downstream of the fifth heat exchanger relative tothe flow of the kerosene pumparound stream. In some implementations, thekerosene pumparound stream can be flowed in series through the differentplants. For example, the kerosene pumparound stream is flowed firstthrough the gas separation plant heat exchanger and then through thearomatics complex plant heat exchanger.

As shown in FIG. 1DK, a kerosene product stream can directly heat asecond amine regenerator bottoms stream in a seventh heat exchanger witha thermal duty that can range between about 5 MW and 15 MW (for example,10.6 MW). The transfer of heat directly to another process streamscaptures heat that would have otherwise been discharged to theenvironment. The kerosene product stream is returned to thehydrocracking plant 712 for further processing.

FIG. 1DL shows a diesel hydrotreating plant 712 in a crude oil refiningfacility. As shown in FIG. 1DL, a diesel stripper overheads stream candirectly heat a second sour water stripper plant bottoms stream in aneighth heat exchanger with a thermal duty that can range between about10 MW and 20 MW (for example, 15.9 MW). The transfer of heat directly toanother process streams captures heat that would have otherwise beendischarged to the environment. The diesel stripper overhead stream isreturned to the hydrocracking plant 712 for further processing.

Also shown in FIG. 1DL, a diesel stripper bottoms stream can directlyheat a second acid gas regenerator bottoms stream in a ninth heatexchanger with a thermal duty that can range between about 15 MW and 25MW (for example, 19.9 MW). The diesel stripper bottoms stream can alsodirectly heat a second C3/C4 splitter bottoms stream in a tenth heatexchanger with a thermal duty that can range between about 1 MW and 10MW (for example, 5.7 MW). As well, the diesel stripper bottoms streamcan also directly heat a de-ethanizer bottoms stream branch in aneleventh heat exchanger with a thermal duty that can range between about1 MW and 10 MW (for example, 4.3 MW). For all three streams, thetransfer of heat directly to another process streams captures heat thatwould have otherwise been discharged to the environment. The dieselproduct stream is returned to the hydrocracking plant 700 for furtherprocessing.

As shown in FIG. 1DL, the eleventh heat exchanger is coupled to, inseries with and is downstream of the tenth heat exchanger relative tothe flow of diesel stripper bottoms stream, and the tenth heat exchangeris coupled to, in series with and is downstream of the ninth heatexchanger relative to the flow of diesel stripper bottoms stream. Insome implementations, the diesel stripper bottoms stream can be flowedin series through the different plants. For example, the diesel stripperbottoms stream is flowed first through the two gas separation plantexchangers and then the amine regeneration plant exchanger. As well, theintra-plant series order, specifically the gas separation plantexchangers, may also be different in alternative embodiments.

FIG. 1DM shows a natural gas steam reforming hydrogen plant 708 in acrude oil refining facility. A low temperature shift (LTS) converterproduct stream can directly heat a third sour water stripper bottomsstream in a twelfth heat exchanger with a thermal duty that can rangebetween about 1 MW and 10 MW (for example, 4.3 MW). The transfer of heatdirectly to another process streams captures heat that would haveotherwise been discharged to the environment. The LTS product stream isreturned to the natural gas steam reforming hydrogen plant 708 forfurther processing.

FIG. 1DP shows an aromatics complex benzene extraction unit 718 in acrude oil refining facility. The heated benzene column bottom stream canbe flowed to the benzene extraction unit 718. The steam heat input forthe benzene column can be 0 MW because the alternative flow pathdisclosed in this configuration may satisfy the entire heat load for theoperation of the column. In an alternative embodiment, the steam heatinput for the benzene column can be reduced because the alternative flowpath disclosed in this configuration may partially satisfy the heat loadfor the operation of the column.

FIG. 1DO also shows an aromatics complex benzene extraction unit 718.The heated raffinate splitter column bottom stream can be flowed to thebenzene extraction plant 718. The steam heat input for the raffinatesplitter can be 0 MW because the alternative flow path disclosed in thisconfiguration may satisfy the entire heat load for the operation of thecolumn. In an alternative embodiment, the steam heat input for theraffinate splitter can be reduced because the alternative flow pathdisclosed in this configuration may partially satisfy the heat load forthe operation of the column.

As shown in FIG. 1DR, the three sour water stripper bottoms streams arerecombined and can be flowed to the sour water stripper plant 710. Inthis manner, the fourth, eighth and twelfth heat exchangers can becoupled to each other in parallel relative to the flow of sour waterstripper bottoms. The steam heat input for the sour water stripper canbe 0 MW because the alternative flow path disclosed in thisconfiguration may satisfy the entire heat load for the operation of thecolumn. In an alternative embodiment, the steam heat input for the sourwater stripper can be reduced because the alternative flow pathdisclosed in this configuration may partially satisfy the heat load forthe operation of the column. In this configuration, the hydrocrackingplant 712, the diesel hydrotreating plant 700, and the natural gas steamreforming hydrogen plant 708 provide energy to the sour water stripperplant 710.

As shown in FIG. 1DN, the two streams of the amine regenerator bottomsare recombined and flowed to the sulfur recovery plant 702. In thismanner, the first heat exchanger and the seventh heat exchanger can becoupled to each other in parallel relative to the flow of amineregenerator bottoms. The steam heat input for the amine regenerator canbe 0 MW because the alternative flow path disclosed in thisconfiguration may satisfy the entire heat load for the operation of thecolumn. In an alternative embodiment, the steam heat input for the amineregenerator can be reduced because the alternative flow path disclosedin this configuration may partially satisfy the heat load for theoperation of the column. In this configuration, only the hydrocrackingplant 712 provide energy to the sulfur recovery plant 702.

As shown in FIG. 1DQ, the two streams of the acid gas regeneratorbottoms are recombined and flowed to the amine regeneration plant 706.In this manner, the third and the ninth heat exchangers can be coupledto each other in parallel relative to the flow of acid gas regeneratorbottoms. The steam heat input for the acid gas regenerator can be 0 MWbecause the alternative flow path disclosed in this configuration maysatisfy the entire heat load for the operation of the column. In analternative embodiment, the steam heat input for the acid gasregenerator can be reduced because the alternative flow path disclosedin this configuration may partially satisfy the heat load for theoperation of the column. In this configuration, both the hydrocrackingplant 712 and diesel hydrotreating plant 700 provide energy to the amineregeneration plant 706.

As shown in FIG. 1DS, the two C3/C4 splitter bottoms streams arerecombined and can be flowed to the gas separation plant 704. In thismanner, the sixth heat exchanger and the tenth heat exchanger can becoupled to each other in parallel relative to the flow of C3/C4 splitterbottoms. The steam heat input for the C3/C4 splitter can be 0 MW becausethe alternative flow path disclosed in this configuration may satisfythe entire heat load for the operation of the column. In an alternativeembodiment, the steam heat input for the C3/C4 splitter can be reducedbecause the alternative flow path disclosed in this configuration maypartially satisfy the heat load for the operation of the column.

As shown in FIG. 1DS, the heated de-ethanizer bottoms stream can also beflowed to the gas separation plant 704. The steam heat input for thede-ethanizer column can be 0 MW because the alternative flow pathdisclosed in this configuration may satisfy the entire heat load for theoperation of the column. In an alternative embodiment, the steam heatinput for the de-ethanizer column can be reduced because the alternativeflow path disclosed in this configuration may partially satisfy the heatload for the operation of the column. In this configuration, both thehydrocracking plant 712 and diesel hydrotreating plant 700 provideenergy to the gas separation plant 704.

Such recovery and reuse of waste heat directly from the hydrocracking,the diesel hydrotreating, and the natural gas steam reforming hydrogenplants can result in decreasing or eliminating the heat energy to heatthe aromatics complex, sulfur recovery plant, an amine regenerationplant, a gas separation plant or a combination of them, such as by about130 MW.

Configuration 11—Scheme B

In some implementations, the multiple streams in the crude oil refiningfacility can be indirectly heated using a buffer fluid, for example,oil, water or other buffer fluid, using the multiple second streams inhydrocracking plant, hydrogen plant, and diesel hydrotreating plant asheat energy sources.

Indirectly heating the streams can include heating the streams through abuffer fluid, for example, oil, water, or other buffer fluid. A bufferfluid (for example, high pressure water) from a buffer fluid tank (forexample, hot water tank) is flowed to the hydrocracking plant 712, thediesel hydrotreating plant 700 and natural gas steam reforming hydrogenplant 708. The buffer fluid can be flowed into each plant as a singlestream and split into multiple streams or it can be flowed into theplant as multiple streams.

To do so, the one or more buffer fluid streams (for example, oil, water,or other buffer fluid) can be heated using streams in the hydrocrackingplant 712, the natural gas steam reforming hydrogen plant 708 and thediesel hydro-treating plant 700 using respective heat exchangers. Theheated buffer fluids can be collected in a buffer fluid collectionheader. Streams in the aromatics complex benzene extraction plant 718,the sour water stripper plant 710, the sulfur recovery plant 702, thegas separation plant 704 and the amine regenerator plant 706 can beheated using heated buffer fluid streams in respective heat exchangers.The heated buffer fluid exiting the heat exchangers can be flowed to abuffer fluid tank. The buffer fluid from the buffer fluid tank can thenbe flowed to the aromatics plant to restart the waste heat recovery andreuse cycle.

In summary, this disclosure describes configurations and relatedprocessing schemes of specific direct or indirect inter-plantsintegration for energy consumption reduction synthesized for grassrootsmedium grade crude oil semi-conversion refineries to increase energyefficiency from specific portions of low grade waste heat sources. Thedisclosure also describes configurations and related processing schemesof specific direct or indirect inter-plants integration for energyconsumption reduction synthesized for integrated medium grade crude oilsemi-conversion refineries and aromatics complex for increasing energyefficiency from specific portions of low grade waste sources.

The economics of industrial production, the limitations of global energysupply, and the realities of environmental conservation are concerns forall industries. It is believed that the world's environment has beennegatively affected by global warming caused, in part, by the release ofGHG into the atmosphere. Implementations of the subject matter describedhere can alleviate some of these concerns, and, in some cases, preventcertain refineries, which are having difficulty in reducing their GHGemissions, from having to shut down. By implementing the techniquesdescribed here, specific plants in a refinery or a refinery, as a whole,can be made more efficient and less polluting by recovery and reusingfrom specific portions of low grade waste heat sources.

Thus, particular implementations of the subject matter have beendescribed. Other implementations are within the scope of the followingclaims.

The invention claimed is:
 1. A method implemented in a crude oilrefining facility, the method comprising: in a crude oil refiningfacility comprising a plurality of oil refining plants, each oilrefining plant configured to perform at least one oil refining process,wherein a plurality of streams at respective temperatures flow betweenthe plurality of oil refining plants: flowing a first plurality ofstreams from a first subset of the plurality of oil refining plants to aplurality of heat exchangers, wherein the first subset comprises anaphtha hydrotreating plant, a gas separation plant, an amineregeneration plant, a sulfur recovery plant, a sour water stripperplant, and an aromatics plant which comprises an aromatics plant xyleneproducts separation unit and an aromatics complex benzene extractionunit, wherein the plurality of first streams comprises a sulfur recoveryplant amine regeneration unit stripper bottom stream in the sulfurrecovery plant, a raffinate splitter bottoms stream in the aromaticscomplex benzene extraction unit, an acid gas regenerator bottoms streamin the amine regeneration plant, a sour water stripper bottoms stream inthe sour water stripper plant, a benzene column bottoms stream in thearomatics complex benzene extraction unit, a C3/C4 stripper bottomstream in the gas separation plant, and a de-ethanizer bottoms stream inthe gas separation plant; flowing a second plurality of streams from asecond subset of the plurality of oil refining plants to the pluralityof heat exchangers, wherein the plurality of heat exchangers transferheat from the first plurality of streams to the second plurality ofstreams, wherein the second subset comprises a hydrogen plant, a dieselhydrotreating plant, and hydrocracking plant wherein the secondplurality of streams comprises a kerosene pumparound stream in thehydrocracking plant, a kerosene product stream in the dieselhydrotreating plant, a diesel stripper overheads stream in the dieselhydrotreating plant, a stripper bottom product stream in the dieselhydrotreating plant, a diesel stripper bottoms stream in the dieselhydrotreating plant, and a low temperature shift converter steam in thehydrogen plant; and utilizing the heated second plurality of streams inone or more oil refining processes at the second subset of the pluralityof oil refining plants.
 2. The method of claim 1, wherein the pluralityof heat exchangers directly transfer heat by: heating, in a first heatexchanger, a branch of the sulfur recovery plant amine regeneration unitstripper bottom stream in the sulfur recovery plant using a dieselproduct stream in the hydrocracking plant; heating, in a second heatexchanger, the raffinate splitter bottoms stream in the aromaticscomplex benzene extraction unit using a second stage reaction sectionfeed to a second stage cold high pressure separator in the hydrocrackingplant; heating, in a third heat exchanger, a branch of the acid gasregenerator bottoms stream in the amine regeneration plant using a firststage reaction section feed to a first stage cold high pressureseparator in the hydrocracking plant; heating, in a fourth heatexchanger, a branch of the sour water stripper bottoms stream in thesour water stripper plant using a stripper overhead stream in thehydrocracking plant; heating, in a fifth heat exchanger, the benzenecolumn bottoms stream in the aromatics complex benzene extraction unitusing a kerosene pumparound stream in the hydrocracking plant; heating,in a sixth heat exchanger, a branch of the C3/C4 stripper bottom streamin the gas separation plant using the kerosene pumparound stream;heating, in a seventh heat exchanger, a branch of the sulfur recoveryplant amine regeneration unit stripper bottom stream using a keroseneproduct stream in the diesel hydrotreating plant; heating, in an eighthheat exchanger, a branch of the sour water stripper bottoms stream usinga diesel stripper overheads stream in the diesel hydrotreating plant;heating, in a ninth heat exchanger, the acid gas bottom stream using astripper bottom product stream in the diesel hydrotreating plant;heating, in a tenth heat exchanger, a branch of the C3/C4 stripperbottom stream using a diesel stripper bottoms stream in the dieselhydrotreating plant; heating, in an eleventh heat exchanger, thede-ethanizer bottoms stream in the gas separation plant using the dieselstripper bottoms stream; heating, in a twelfth heat exchanger, a branchof the sour water stripper bottoms stream using a low temperature shiftconverter steam in the hydrogen plant; flowing the heated benzene columnbottoms stream and the raffinate splitter bottoms stream to thearomatics complex benzene extraction unit; flowing the branches of theheated sour water stripper streams to the sour water stripper plant;flowing the branches of the heated C3/C4 splitter bottom streams and thede-ethanizer bottoms stream to the gas separation plant; flowing thebranches of the heated sulfur recovery plant amine regeneration unitstripper bottom stream to the sulfur recovery plant; and flowing thebranches of the heated acid gas regenerator bottoms streams to the amineregeneration plant.